Platform and method of operating for integrated end-to-end area-selective deposition process

ABSTRACT

A method is provided for area-selective deposition on a semiconductor workpiece using an integrated sequence of processing steps executed on a common manufacturing platform hosting one or more film-forming modules, one or more etching modules, and one or more transfer modules. A workpiece having a target surface of a first material and a non-target surface of a second material different than the first material is received into the common manufacturing platform. An additive material is deposited on the workpiece with selectivity that results in the additive material forming on the target surface at a higher deposition rate than on the non-target surface, followed by etching to expose the non-target surface. The integrated sequence of processing steps is executed within the common manufacturing platform without leaving the controlled environment and the transfer modules are used to transfer the workpiece between the processing modules while maintaining the workpiece within the controlled environment.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims the benefit of U.S. ProvisionalApplication No. 62/645,685, filed on Mar. 20, 2018, entitled “SubstrateProcessing Tool with Integrated Metrology and Method of Using,” U.S.Provisional Application No. 62/784,155, filed on Dec. 21, 2018 entitled“Platform and Method for Operating for Integrated End-to-End AreaSelective Deposition Process,” U.S. Provisional Application No.62/787,607, filed on Jan. 2, 2019, entitled “Self-Aware and CorrectingHeterogeneous Platform incorporating Integrated Semiconductor ProcessingModules and Method for using same,” U.S. Provisional Application No.62/787,608, filed on Jan. 2, 2019, entitled “Self-Aware and CorrectingHeterogeneous Platform incorporating Integrated Semiconductor ProcessingModules and Method for using same,” and U.S. Provisional Application No.62/788,195, filed on Jan. 4, 2019, entitled “Substrate Processing Toolwith Integrated Metrology and Method of using,” which is incorporatedherein by reference in its entirety.

BACKGROUND OF THE INVENTION Field of the Invention

The present invention relates to a processing platform and methods forsemiconductor processing using the platform, and more particularly to amethod for area-selective deposition (ASD).

Background of the Invention

Dimension shrinkage is one of the driving forces in the development ofintegrated circuit processing. By reducing the size dimensions,cost-benefit and device performance boosts can be obtained. Thisscalability creates inevitable complexity in process flow, especially onpatterning techniques. For example, as smaller circuits such astransistors are manufactured, the critical dimension (CD) or resolutionof patterned features is becoming more challenging to produce,particularly in high volume. Self-aligned patterning needs to replaceoverlay-driven patterning so that cost-effective scaling can continueeven after the introduction of extreme ultraviolet (EUV) lithography.Patterning options that enable reduced variability, extend scaling, andenhance CD and process control are needed in a high-volume manufacturingenvironment; however, it is getting extremely difficult to producescaled devices at reasonably low cost and high yield. Selectivedeposition, together with selective etch, can significantly reduce thecost associated with advanced patterning. Selective deposition of thinfilms such as gap fill, area selective deposition of dielectrics andmetals on specific substrates, and selective hard masks are key steps inpatterning in highly scaled technology nodes.

As devices are scaled to smaller and smaller features and techniques areimplemented to try and address the issues that result from scaling, itis important to monitor the fabrication process at various stages of theprocess flow to determine whether the feature attributes are withinspecification, and if not, to adjust the process to either bring theworkpiece within specification or to bring subsequently processedworkpieces within specification.

In conventional device fabrication, the process steps are performedusing multiple separate stand-alone tools for high-volume manufacturing.Wafers are sequentially loaded into one tool, subjected to one processstep in that tool, then removed to ambient environment and placed inqueue to be loaded into the next tool, and so on until the multiplesteps of a given process flow are complete. Time spent waiting in queuefor each tool is referred to as Q-time, and high Q-times result in lowerproduction rates. Different operations in the process flow may takedifferent amounts of time such that throughput matching of tools is aproduction challenge.

Each tool in the process flow may be part of a tool cluster. Forexample, five identical etch tools can be clustered in combination witha transfer tool so that 5 wafers can be etched concurrently at one stepof the process flow to enable high-volume production. The multiplicityof these cluster tools provides a benefit if a tool goes out of servicefor any reason. If 1 tool in a 5-tool cluster goes out of service for 1week, then production can continue, albeit at only 80% capacity. Thus,each stand-alone tool in the process flow may be a cluster of identicaltools to prevent an out of service tool from shutting down productioncompletely, and clustering may be used to minimize throughput matchingchallenges.

In conventional processing, if measurements are needed to determinewhether a process is operating within specification, a stand-alonemetrology tool may be included, where a workpiece is periodicallyremoved from the process flow for measurements to be taken, which areoften destructive measurements using a measurement pad on the workpiece,and the results can be fed back to the process flow tools foradjustments to downstream steps in the process flow, or adjustments toupstream steps for future wafers. This process involves exposure to theambient environment, Q-time waiting for the metrology tool to beavailable, and lengthy measurement times for results to be obtained,such that significant time may pass before data is available to enableadjustments to be made to the process flow in either a feed-back orfeed-forward manner. While real-time measurements of workpieceattributes taken in the process chamber would be ideal, exposure of themeasurement devices to process gases is problematic, making real-time,in situ measurement and control logistically difficult or impossible.

Thus, the conventional approach of using multiple separate stand-alonetools (single or clustered) for high-volume manufacturing can lead toissues including but not limited to Q-time oxidation (i.e., as thewafers sit between tools waiting for their turn in the next tool, theycan be subjected to oxidation from the ambient environment), defectivityfrom environmental exposure between tools, cost challenges due tothroughput matching difficulties, temporal tool drift (e.g., EPE), realtime chamber matching (e.g., yield and EPE), and lack of real-timeworkpiece measurement and process control. There is a need to addressthese and other issues to enable high-volume manufacturing witharea-selective deposition (ASD) techniques.

SUMMARY OF THE INVENTION

According to embodiments, a method of selective deposition on asemiconductor workpiece is provided using an integrated sequence ofprocessing steps executed on a common manufacturing platform hosting aplurality of processing modules including one or more film-formingmodules, one or more etching modules, and one or more transfer modules.In one embodiment, the integrated sequence of processing steps includesreceiving a workpiece into the common manufacturing platform, theworkpiece having at least one target surface of a first material and atleast one non-target surface of a second material different than thefirst material, and depositing an additive material on the workpiece inone of the one or more film-forming modules. The depositing is withselectivity relative to the non-target surfaces that results in a layerof the additive material forming on the target surfaces at a higherdeposition rate than on the non-target surfaces. The integrated sequenceof processing steps further includes etching the workpiece in one ormore etching modules to remove undesired additive material from thenon-target surfaces, and repeating the depositing and etching until thelayer of additive material formed on the target surfaces reaches atarget thickness. The integrated sequence of processing steps isexecuted in a controlled environment within the common manufacturingplatform and without leaving the controlled environment, and the one ormore transfer modules are used to transfer the workpiece between theplurality of processing modules while maintaining the workpiece withinthe controlled environment.

In a related embodiment, the integrated sequence of processing steps mayfurther comprise pre-treating the workpiece before depositing the layerof additive material, or during subsequent deposition steps, to alter asurface termination of a target surface, or a surface termination of anon-target surface, or a combination thereof, with the plurality ofprocessing modules hosted on the common manufacturing platform includingone or more pre-treatment modules for performing the pre-treating in thecontrolled environment.

In one embodiment, the integrated sequence of processing steps includesreceiving a workpiece into the common manufacturing platform, theworkpiece having a target surface of a first material and a non-targetsurface of a second material different than the first material, anddepositing an additive material on the workpiece in one or morefilm-forming modules. The depositing is with selectivity relative to thenon-target surfaces that results in a layer of the additive materialforming on the target surfaces at a higher deposition rate than on thenon-target surfaces. The integrated sequence of processing steps furtherincludes etching the workpiece in one of the one or more etching modulesto remove undesired additive material from the non-target surfaces, andinspecting the additive material on the target surfaces and/or thenon-target surfaces to determine defectivity, thickness, uniformity,and/or selectivity of the additive material on the workpiece. When theinspecting indicates a defectivity, surface termination, uniformity,and/or selectivity of the additive material or a target or non-targetmaterial does not meet a target threshold, a corrective action isperformed on the workpiece by (i) etching the target surface, (ii)etching the non-target surface, (iii) depositing further additivematerial on the workpiece, (iv) thermally treating the workpiece, (v)plasma treating the workpiece, (vi) etching the additive material, (vii)performing a surface treatment to alter the surface termination of atarget surface or a non-target surface, or any combination of two ormore thereof. The depositing, etching, and inspecting of the workpieceare repeated when a thickness of the layer of additive material on thetarget surface is less than a target thickness. The integrated sequenceof processing steps is executed in a controlled environment within thecommon manufacturing platform and without leaving the controlledenvironment, and the one or more transfer modules are used to transferthe workpiece between the plurality of processing modules whilemaintaining the workpiece within the controlled environment.

In a related embodiment, the integrated sequence of processing steps mayfurther comprise pre-treating the workpiece before depositing the layerof additive material to alter a surface termination of the targetsurface, or a surface termination of the non-target surface, or acombination thereof, with the plurality of processing modules hosted onthe common manufacturing platform including one or more pre-treatmentmodules for performing the pre-treating in the controlled environment.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above, andthe detailed description given below, serve to explain the invention.

FIGS. 1A-1D are schematic cross-sectional views of methods ofarea-selective film formation according to embodiments of the invention;

FIGS. 2A-2D illustrate in schematic cross-sectional view an integratedsequence of processing steps according to one embodiment of anarea-selective deposition method;

FIG. 3 is a flow chart diagram illustrating one embodiment of anintegrated process flow for area-selective deposition;

FIG. 4 is a schematic diagram illustrating one embodiment of a commonmanufacturing platform for performing an integrated area-selectivedeposition method;

FIGS. 5A-5D illustrate in schematic cross-sectional view an integratedsequence of processing steps according to another embodiment of anarea-selective deposition method;

FIG. 6 is a schematic diagram illustrating one embodiment of a commonmanufacturing platform for performing an integrated sequence ofprocessing steps;

FIG. 7A is a schematic diagram illustrating in top view anotherembodiment of a common manufacturing platform for performing anintegrated sequence of processing steps, and FIG. 7B is a side view inpartial cross-section of a measurement module incorporated in the commonmanufacturing platform of FIG. 7A.

FIG. 7C is a schematic diagram illustrating in top view anotherembodiment of a common manufacturing platform for performing anintegrated sequence of processing steps, and FIG. 7D is a side view inpartial cross-section of a measurement module incorporated in the commonmanufacturing platform of FIG. 7C.

DETAILED DESCRIPTION

Methods using an integrated platform for area-selective deposition (ASD)are presented. However, one skilled in the relevant art will recognizethat the various embodiments may be practiced without one or more of thespecific details, or with other replacement and/or additional methods,materials, or components. In other instances, well-known structures,materials, or operations are not shown or described in detail to avoidobscuring aspects of various embodiments of the invention.

Similarly, for purposes of explanation, specific numbers, materials, andconfigurations are set forth in order to provide a thoroughunderstanding of the invention. Nevertheless, the invention may bepracticed without specific details. Furthermore, it is understood thatthe various embodiments shown in the figures are illustrativerepresentations and are not necessarily drawn to scale. In referencingthe figures, like numerals refer to like parts throughout.

Reference throughout this specification to “one embodiment” or “anembodiment” or variation thereof means that a particular feature,structure, material, or characteristic described in connection with theembodiment is included in at least one embodiment of the invention butdoes not denote that it is present in every embodiment. Thus, thephrases such as “in one embodiment” or “in an embodiment” that mayappear in various places throughout this specification are notnecessarily referring to the same embodiment of the invention.Furthermore, the particular features, structures, materials, orcharacteristics may be combined in any suitable manner in one or moreembodiments. Various additional layers and/or structures may be includedand/or described features may be omitted in other embodiments.

Additionally, it is to be understood that “the”, “a” or “an” may mean“one or more” unless explicitly stated otherwise.

Various operations will be described as multiple discrete operations inturn, in a manner that is most helpful in understanding the invention.However, the order of description should not be construed as to implythat these operations are necessarily order dependent. In particular,these operations need not be performed in the order of presentation.Operations described may be performed in a different order than thedescribed embodiment. Various additional operations may be performedand/or described operations may be omitted in additional embodiments.

As used herein, the term “substrate” means and includes a base materialor construction upon which materials are formed. It will be appreciatedthat the substrate may include a single material, a plurality of layersof different materials, a layer or layers having regions of differentmaterials or different structures in them, etc. These materials mayinclude semiconductors, insulators, conductors, or combinations thereof.For example, the substrate may be a semiconductor substrate, a basesemiconductor layer on a supporting structure, a metal electrode or asemiconductor substrate having one or more layers, structures or regionsformed thereon. The substrate may be a conventional silicon substrate orother bulk substrate comprising a layer of semi-conductive material. Asused herein, the term “bulk substrate” means and includes not onlysilicon wafers, but also silicon-on-insulator (“SOI”) substrates, suchas silicon-on-sapphire (“SOS”) substrates and silicon-on-glass (“SOG”)substrates, epitaxial layers of silicon on a base semiconductorfoundation, and other semiconductor or optoelectronic materials, such assilicon-germanium, germanium, gallium arsenide, gallium nitride, andindium phosphide. The substrate may be doped or undoped.

As used herein the term “workpiece” means a composition of materials orlayers formed on a substrate during one or more phases of asemiconductor device manufacturing process, the workpiece ultimatelycomprising the semiconductor device at a final stage of processing.

The present embodiments include methods for ASD that utilize a commonmanufacturing platform in which multiple process steps are performed onthe common platform within a controlled environment, for example,without breaking vacuum between operations. The integrated end-to-endplatform includes both etching modules and film-forming modules and isconfigured to transfer a workpiece from one module to another whilemaintaining the workpiece in a controlled environment, e.g., withoutbreaking vacuum or leaving an inert gas protective environment withinthe common manufacturing platform, and thus avoiding exposure to anambient environment. Any ASD process may be carried out on the commonmanufacturing platform, and the integrated end-to-end platform willenable high-volume manufacturing at reduced cost with improvement toyield, defectivity levels and EPE.

As used herein, a “film-forming module” refers to any type of processingtool for depositing or growing a film or layer on a workpiece in aprocess chamber. The film-forming module may be a single wafer tool, abatch processing tool, or a semi-batch processing tool. The types offilm deposition or growth that may be performed in the film-formingmodule include, by way of example and not limitation, chemical vapordeposition, plasma-enhanced or plasma-assisted chemical vapordeposition, atomic layer deposition, physical vapor deposition, thermaloxidation or nitridation, etc., and the process may be isotropic,anisotropic, conformal, selective, blanket, etc.

As used herein, an “etching module” refers to any type of processingtool for removing all or a portion of a film, layer, residue orcontaminant on a workpiece in a process chamber. The etching module maybe a single wafer tool, a batch processing tool, or a semi-batchprocessing tool. The types of etching that may be performed in theetching module include, by way of example and not limitation, chemicaloxide removal (COR), dry (plasma) etching, reactive ion etching, wetetching using immersion or non-immersion techniques, atomic layeretching, chemical-mechanical polishing, cleaning, ashing, lithography,etc., and the process may be isotropic, anisotropic, selective, etc.

As used herein, “module” generally refers to a processing tool with allof its hardware and software collectively, including the processchamber, substrate holder and movement mechanisms, gas supply anddistribution systems, pumping systems, electrical systems andcontrollers, etc. Such details of the modules are known in the art andtherefore not discussed herein.

“Controlled environment” as used herein refers to an environment inwhich the ambient atmosphere is evacuated and either replaced with apurified inert gas or a low-pressure vacuum environment. A vacuumenvironment is well below atmospheric pressure and is generallyunderstood to be 10⁻⁵ Torr or less, for example 5×10⁻⁸ Torr or less.{Please refine definition as appropriate—to be added to all processcases}

In its broadest terms, embodiments of the disclosure relate to anintegrated sequence of processing steps performed on a workpiece andexecuted on a common manufacturing platform hosting a plurality ofprocessing modules including one or more film-forming modules, one ormore etching modules, and one or more transfer modules. The integratedsequence of processing steps includes receiving a workpiece into thecommon manufacturing platform, the workpiece having a target surface ofa first material and a non-target surface of a second material differentthan the first material. Using the one or more film-forming modules, anadditive material is deposited on the workpiece with selectivityrelative to the non-target surface that results in a layer of theadditive material forming on the target surface at a higher depositionrate than on the non-target surface. Then, using the one or more etchingmodules, the workpiece is etched to expose the non-target surface. Theintegrated sequence of processing steps is repeated until the layer ofadditive material reaches a target thickness. Further, the integratedsequence of processing steps is executed in a controlled environmentwithin the common manufacturing platform and without leaving thecontrolled environment, and the one or more transfer modules are used totransfer the workpiece between the plurality of processing modules whilemaintaining the workpiece within the controlled environment.

Embodiments may include one of the first and second materials being ametal and the other of the first and second materials being a dielectricmaterial. The additive material may be a metal or a dielectric material.Thus, the integrated sequence of processing steps may be directed tometal-on-metal ASD, dielectric-on-dielectric ASD, metal-on-dielectricASD, or dielectric-on-metal ASD. The metal for any of the targetsurface, the non-target surface, or the additive material may include,by way of example and not limitation, Cu, Al, Ta, TaN, Ti, TiN, W, Ru,Co, Ni, or Mo. The dielectric material for any of the target surface,the non-target surface, or the additive material may include, by way ofexample and not limitation, Sift, a low-k dielectric material, or ahigh-k dielectric material. Low-k dielectric materials have a nominaldielectric constant less than the dielectric constant of SiO₂, which isapproximately 4 (e.g., the dielectric constant for thermally grownsilicon dioxide can range from 3.8 to 3.9). High-k materials have anominal dielectric constant greater than the dielectric constant ofSiO₂.

Low-k dielectric materials may have a dielectric constant of less than3.7, or a dielectric constant ranging from 1.6 to 3.7. Low-k dielectricmaterials can include fluorinated silicon glass (FSG), carbon dopedoxide, a polymer, a SiCOH-containing low-k material, a non-porous low-kmaterial, a porous low-k material, a spin-on dielectric (SOD) low-kmaterial, or any other suitable dielectric material. The low-kdielectric material can include BLACK DIAMOND® (BD) or BLACK DIAMOND® II(BDII) SiCOH material, commercially available from Applied Materials,Inc., or Coral® CVD films commercially available from Novellus Systems,Inc. Other commercially available carbon-containing materials includeSILK® (e.g., SiLK-I, SiLK-J, SiLK-H, SiLK-D, and porous SiLKsemiconductor dielectric resins) and CYCLOTENE® (benzocyclobutene)available from Dow Chemical, and GX-3™ and GX-3P™ semiconductordielectric resins available from Honeywell.

Low-k dielectric materials include porous inorganic-organic hybrid filmscomprised of a single-phase, such as a silicon oxide-based matrix havingCH₃ bonds that hinder full densification of the film during a curing ordeposition process to create small voids (or pores). Stillalternatively, these dielectric layers may include porousinorganic-organic hybrid films comprised of at least two phases, such asa carbon-doped silicon oxide-based matrix having pores of organicmaterial (e.g., porogen) that is decomposed and evaporated during acuring process.

In addition, low-k materials include a silicate-based material, such ashydrogen silsesquioxane (HSQ) or methyl silsesquioxane (MSQ), depositedusing SOD techniques. Examples of such films include FOx® HSQcommercially available from Dow Corning, XLK porous HSQ commerciallyavailable from Dow Corning, and JSR LKD-5109 commercially available fromJSR Microelectronics.

In one example, the dielectric material, particularly when used as theadditive material, may include a metal oxide that contains TiO₂, HfO₂,ZrO₂, or Al₂O₃. Such metal oxides may, for example, be deposited by CVD,plasma-enhanced CVD PEALD), ALD or plasma-enhanced ALD (PEALD). In someexamples, the metal oxide may be deposited by ALD using alternatingexposures of a metal-containing precursor and an oxidizer (e.g., H₂O,H₂O₂, plasma-excited O₂, or O₃).

Embodiments of the invention address integrated substrate processing forASD and the need for performing substrate metrology during theintegrated substrate processing. During ASD, substrate metrology may beperformed within the common manufacturing platform following thedeposition step, for example, to measure and characterize loss ofdeposition selectivity and, based on substrate metrology data, performremoval of undesired film nuclei to achieve selective formation. Theresults from the substrate metrology step may be used to tune the filmnuclei removal step based on variation in the film deposition step.Further, artificial intelligence (AI) may be used to analyze thesubstrate metrology results and predict future film thickness and filmdeposition selectivity.

Reference is now made to the drawings, where like reference numeralsdesignate identical or corresponding parts throughout the several views.

FIGS. 1A-1D schematically depict embodiments of ASD in which an additivematerial is selectively deposited on a target surface of a firstmaterial with selectivity relative to a non-target surface of a secondmaterial different than the first material such that a layer of theadditive material forms on the target surface at a higher depositionrate than on the non-target surface. In FIG. 1A, metal-on-metal (MoM)selective deposition is shown on a planar surface of a workpiece 100.The workpiece 100 includes a substrate 110, such as a Si wafer. Theworkpiece further includes a target metal surface 112 and a non-targetdielectric surface 114 that together form a planar surface 116. A metaladditive material 118 is deposited on the target metal surface 112 toform an elevated metal pattern above the planar surface 116. The metaladditive material 118 may be deposited layer by layer until a targetvertical height above the planar surface 116 is reached, or a targetstep-height distance, d, is reached.

In FIG. 1B, MoM selective deposition is shown in a recessed metalfeature pattern. The workpiece 102 includes a metal layer 120, which maybe formed on one or more underlying layers (not shown), and a patternedinterlayer dielectric 122 formed thereon to expose portions of the metallayer 120, which exposed portions form the target metal surface 124. Tostate another way, the target metal surface 124 is the exposed bottomsurfaces of the recessed metal feature pattern formed in the interlayerdielectric 122, and the upper field or planar surface 126 of theinterlayer dielectric 122 forms the non-target dielectric surface 126. Ametal additive material 128 is deposited on the target metal surface 124to at least partially fill the recessed metal feature pattern. The metaladditive material 128 may be deposited layer by layer until a targetfill level at or below the upper planar surface 126 is reached, or atarget change in the step-height distance, d, is reached.

In FIG. 1C, dielectric-on-dielectric (DoD) selective deposition is shownon a planar surface. The workpiece 104 includes a substrate 130, such asa Si wafer. The workpiece further includes a target dielectric surface132 and a non-target metal surface 134 that together form a planarsurface 136. A dielectric additive material 138 is deposited on thetarget dielectric surface 132 to form an elevated dielectric patternabove the planar surface 136. The dielectric additive material 138 maybe deposited layer by layer until a target vertical height above theplanar surface 136 is reached, or a target step-height distance, d, isreached.

In FIG. 1D, DoD selective deposition is shown in a dielectric trenchpattern. The workpiece 106 includes a dielectric layer 140, which may beformed on one or more underlying layers (not shown), and a plurality ofmetal lines 142 formed thereon to expose portions of the dielectriclayer 140, which exposed portions form the target dielectric surface144. To state another way, the target dielectric surface 144 is theexposed bottom surfaces of the dielectric trench pattern formed betweenthe metal lines 142, and the upper planar surface 146 of the metal lines142 forms the non-target metal surface 146. A dielectric additivematerial 148 is deposited on the target dielectric surface 144 to atleast partially fill the dielectric trench pattern. The dielectricadditive material 148 may be deposited layer by layer until a targetfill level at or below the upper planar surface 146 is reached, or atarget change in the step-height distance, d, is reached.

As stated previously, the additive material is deposited on the targetsurface with a selectivity relative to the non-target surface such thata layer of the additive material forms on the target surface at a higherdeposition rate than on the non-target surface. Ideally, the selectivityis high enough that a target thickness of additive material is reachedon the target surface before any deposition occurs on the non-targetsurface, i.e., the deposition rate on the target surface is relativelyfast and the deposition rate on the non-target surface is extremelyslow. In practice, however, some deposition may occur on the non-targetsurface, anywhere from a small number of nuclei as a contaminant to acomplete layer of additive material. In all cases, the additive materialon the non-target surface will have a thickness less than the thicknesson the target surface due to the selectivity and thus higher depositionrate on the target surface. To address any deposition that occurs on thenon-target surface, an etching step is performed after the selectivedeposition to remove additive material from the non-target surface so asto re-expose the non-target surface.

In an embodiment, the integrated sequence of processing steps furthercomprises a pre-treatment of the workpiece before depositing the layerof additive material. The pre-treatment is performed to alter one orboth of the target and non-target surfaces. The pre-treatment may cleana surface, de-oxidize a surface, oxidize a surface, form a barrier layeron a surface, or alter a surface termination on a surface, or anycombination thereof, and may include a single pre-treatment step ormultiple pre-treatment steps. The common manufacturing platform mayinclude one or more pre-treatment modules for performing thepre-treatment(s) in the controlled environment. The pre-treatmentmodule(s) may be a film-forming module, an etching module, or other gasor plasma treatment module. In one example, a pre-treatment module isincluded in the common manufacturing platform for depositing or forminga barrier or blocking layer to inhibit deposition of the additivematerial on the non-target surface and to provide increased selectivitytoward the target surface relative to the non-target surface. Forexample, the pre-treatment may increase the selectivity to a value of atleast 10:1, or at least 100:1. In an embodiment, the workpiece istreated to add surface termination groups. The non-target surface may betreated to add termination groups that are less reactive with theadditive material to thereby inhibit deposition thereon, or the targetsurface may be treated to add termination groups that are more reactivewith the additive material to thereby promote deposition thereon. Forexample, hydrophobic termination groups may be added to a non-targetoxide surface to inhibit deposition of metal on the oxide. In anotherexample, a target metal surface is de-oxidized to promote deposition ofmetal on the oxide-free metal surface.

In an embodiment, the integrated sequence of processing steps comprisesa pre-treatment of the workpiece to form a self-assembled monolayer(SAM) on the non-target surface. The SAM may be formed by exposing theworkpiece to a reactant gas that contains a molecule that is capable offorming a SAM on the surface. The SAM is a molecular assembly that isformed spontaneously on substrate surfaces by adsorption and organizedinto more or less large ordered domains. The SAM can include a moleculethat possesses a head group, a tail group, and a functional end group,and the SAM is created by the chemisorption of head groups onto thesurface from the vapor phase at room temperature or above roomtemperature, followed by a slow organization of the tail groups.Initially, at small molecular density on the surface, adsorbatemolecules form either a disordered mass of molecules or form an orderedtwo-dimensional “lying down phase,” and at higher molecular coverage,over a period of minutes to hours, begin to form three-dimensionalordered or semi-ordered structures on the surface. The head groupsassemble together at reactive sites on the surface, while the tailgroups assemble normal to the surface.

According to one embodiment, the head group of the molecule forming theSAM can include a thiol, a silane, an amine, a phosphonic acid or aphosphonate. Examples of silanes include molecules that include C, H,Cl, F, and Si atoms, or C, H, Cl, and Si atoms. Non-limiting examples ofthe molecule include perfluorodecyltrichlorosilane(CF₃(CF₂)₇CH₂CH₂SiCl₃), perfluorodecanethiol (CF₃(CF₂)₇CH₂CH₂SH),chlorodecyldimethylsilane (CH₃(CH₂)₈CH₂Si(CH₃)₂Cl), andtertbutyl(chloro)dimethylsilane ((CH₃)₃CSi(CH₃)₂Cl)).

The presence of the SAM on the non-target surface may be used to enablesubsequent selective deposition on the target surface (e.g., adielectric layer) relative to the non-target surface (e.g., a metallayer). This selective deposition behavior provides a method forselectively depositing a film on the target surface while preventing orreducing deposition on the non-target surface.

According to a further embodiment, where a pre-treatment step isperformed on the non-target surface, the etching step may remove thepre-treatment layer in addition to any additive material that depositson the non-target surface, in one or more etching steps. Also, where thedeposition and etching steps are repeated to build up the additivematerial on the target surface layer-by-layer, the pre-treatment maylikewise be repeated before each deposition step, or less frequently asdesired or needed, such as every 5^(th) or 10^(th) repetition, or it maynot need to be repeated, for example, repeating de-oxidation may not beneeded if the workpiece is maintained in the controlled environment andnot exposed to an oxidizing environment. Removal and subsequent repeateddeposition of the SAM may be desired if the SAM becomes damaged duringdeposition of the additive material and/or during the etching processand therefore negatively affects deposition selectivity.

FIGS. 2A-2D illustrate one embodiment of an area-selective deposition(ASD) method for a workpiece. FIG. 3 is a flow chart of a process flow300 corresponding to the method of FIGS. 2A-2D. FIG. 4 illustrates anembodiment of a common manufacturing platform of the invention that maybe used for performing process flow 300. The process flow 300 of FIG. 3and the common manufacturing platform 400 of FIG. 4 will be referencedthroughout the following sequential discussion of FIGS. 2A-2D in which aworkpiece 200 is described as it proceeds through an integrated sequenceof processing steps.

In operation 302 of process flow 300 and as shown in FIG. 2A, workpiece200 is provided into the common manufacturing platform 400. Theworkpiece 200 may include any number of material layers formed on asubstrate 210, but at a minimum, the workpiece 200 includes a targetsurface 220 of a first material and a non-target surface 230 of a secondmaterial different than the first material. The target and non-targetsurfaces 220, 230 may form a planar surface, as shown, similar to FIGS.1A and 1C, or may have an initial step-height difference, similar toFIGS. 1B and 1D. The workpiece 200 may thus have any pattern formedthereon comprising at least first and second dissimilar materials withat least one target surface 220 of the first material exposed upon whichdeposition is desired, and at least one non-target surface 230 of thesecond material exposed upon which deposition is not desired. In theembodiment depicted in FIGS. 2A-2D, the first material is a dielectricmaterial, for example an oxide, such that the target surface 220 is atarget dielectric surface, and the second material is a metal such thatthe non-target surface 230 is a non-target metal surface. The additivematerial to be deposited on the target dielectric surface 220 may be thesame or different dielectric material as the first material or may be ametal.

As shown in FIG. 4, a transfer module 410 a may be used to bring theworkpiece into the controlled environment of the common manufacturingplatform 400, which controlled environment is maintained throughout theprocess flow 300. The controlled environment may include a vacuumenvironment, where each operation in the process flow 300 is conductedwithout breaking vacuum, or an inert gas atmosphere, or a combinationthereof. A single transfer module may be coupled between each processingmodule or tool, or separate transfer modules 410 may be used for eachtool transfer, as depicted in FIG. 4. Transfer modules 410 a-e may becollectively referred to herein as transfer modules 410 whereappropriate. Where different processing modules on the commonmanufacturing platform 400 require different controlled environments,such as different vacuum pressures or vacuum in one module followed by amodule with inert gas atmosphere, multiple transfer modules 410 may beused where the transfer modules 410 assist in implementing thetransitions between the different controlled environments. While asingle transfer module may be useful in a cluster-type tool wheresame-type processing modules are positioned in a circle around thetransfer module, multiple transfer modules 410 may be more appropriatein an end-to-end platform configuration with different processing moduletypes such as that depicted in FIG. 4. However, the embodiments hereindo not preclude an end-to-end platform configuration that utilizes asingle transfer module that is coupled to each of the processingmodules, or some configuration in between, for example, a commontransfer module for adjacent same-type processing modules that are usedin sequence.

As is well known in high volume manufacturing, a front-end module 402 amay be used to load a cassette of workpieces (not shown), sequentiallyline up the workpieces and insert them into a load lock, then into atransfer module 410 a in a controlled environment, and the transfermodule 410 a sequentially loads the workpieces into a processing module.In the common manufacturing platform 400 of an embodiment of theinvention, in operation 302, the workpiece 200, which has been receivedinto the controlled environment, is loaded by the transfer module 410 ainto a first pre-treatment module 415 hosted on the common manufacturingplatform 400.

Referring to FIGS. 3 and 4, in optional operation 304, in the firstpre-treatment module 415, a first pre-treatment process is performed toexpose the workpiece 200 to a treatment gas. For example, the treatmentgas can include an oxidizing gas or a reducing gas. In some examples,the oxidizing gas can include O₃, O₂, H₂O, H₂O₂, isopropyl alcohol, or acombination thereof, and the reducing gas can include silane, disilane,trisilane, trimethylaluminum, NH₃, BH₃, PH₃, H₂ gas. In one example, thetreatment gas can include or consist of a plasma-excited. The plasmaexcited gas may for example be an oxidizing gas, a reducing gas, or areducing gas. In another example, the a bias may be applied to thesubstrate, to a portion or part of the treatment module, or acombination thereof during the exposing to the treatment gas. Thetreatment gas can clean or alter the surface of either the targetdielectric surface 220 or the non-target metal surface 230 to improvesubsequent ASD. The treatment gas can form a blocking layer on thenon-target surface by reacting with surface groups on the non-targetsurface. In another example the treatment gas can form a nucleationlayer on the target surface. In another example the treatment gas canform a self-assembled monolayer (SAM) on a target surface or on anon-target surface.

Referring to FIGS. 2B, 3 and 4, and further in optional operation 304,without leaving the controlled environment, e.g., without breakingvacuum, transfer modules 410 a and 410 b are used to transfer theworkpiece 200 to a second pre-treatment module 415. In the secondpre-treatment module 415, a second pre-treatment process is performed torender the non-target metal surface 230 less attractive or reactive tothe additive material to be deposited on the target dielectric surface220. As shown, the pre-treatment may include a barrier layer 240 beingselectively deposited over the non-target metal surface 230 to inhibitdeposition of the additive material thereon and to increase theselectivity toward the target dielectric surface 220. The barrier layer240 may be a SAM or any other surface treatment layer that has theeffect of inhibiting deposition of the additive material on the treatedsurface. While barrier layer 240 may be referred to as SAM 240 in thefollowing discussion, it may be appreciated that the invention is notlimited solely to a SAM as a barrier layer. The SAM 240 may be depositedon the exposed non-target metal surface 230, as shown, or may convert asurface portion of the exposed non-target metal surface 230 to a barrierlayer, or a combination thereof. As shown, the common manufacturingplatform 400 may include identical pre-treatment modules 415 on opposingsides of the transfer modules 410 a, 410 b. By mirroring the two sidesof the platform 400, end-to-end processing can be achieved for twoworkpieces concurrently, and if one pre-treatment module 415 goes out ofservice temporarily, the platform 400 can continue to operate, at leastat 50% capacity.

Then, without leaving the controlled environment, e.g., without breakingvacuum, transfer modules 410 b and 410 c are used to transfer theworkpiece 200 to a film-forming module 420. Referring to FIGS. 2C and 3,in operation 306, in the film-forming module 420, dielectric additivematerial 250 is selectively deposited on the target dielectric surface132 to form an elevated dielectric pattern. Due to the selectivitytoward the target surface 220 relative to the SAM 240 on the non-targetsurface 230, a layer of the dielectric additive material 250 forms onthe target dielectric surface 220 at a higher deposition rate than onthe non-target surface 230. In one example, the dielectric additivematerial 250 may include a metal oxide film that contains HfO₂, ZrO₂, orAl₂O₃. The dielectric additive material 250 may, for example, bedeposited by CVD, plasma-enhanced CVD PEALD), ALD or plasma-enhanced ALD(PEALD). In some examples, the dielectric additive material 250 may bedeposited by ALD using alternating exposures of a metal-containingprecursor and an oxidizer (e.g., H₂O, H₂O₂, plasma-excited O₂, or O₃).Again, the common manufacturing platform 400 may include two identicalfilm-forming modules 420 on opposing sides of the transfer module 410 c.

As depicted in FIG. 2C, the exposure to deposition gases in film-formingmodule 420 may, in addition to depositing the dielectric additivematerial 250 on the target dielectric surface 220, deposit film nuclei260 on the SAM 240 as a result of a loss of selectivity or insufficientselectivity. Loss of deposition selectivity can occur, for example, ifthe deposition process is carried out for too long. Insufficient or poordeposition selectivity can occur, for example, if surface coverage ofthe SAM 208 is incomplete and contains voids on the non-target surface230.

Referring to FIGS. 2D and 3, in operation 308, and without leaving thecontrolled environment, e.g., without breaking vacuum, the workpiece 200is transferred to one or more etching modules to perform one or moreetching steps to expose the non-target surface 230 and thereby achievethe ASD on the target surface 220. In this example, and as shown in FIG.4, two etching steps are performed sequentially in first and secondetching modules 430, to first remove the film nuclei 260 and then removethe SAM 240. Transfer modules 410 c and 410 d are used to transfer theworkpiece 200 to a first etching module 430 hosted on the commonmanufacturing platform 400, e.g., transfer module 410 c removes theworkpiece 200 from film-forming module 420 and transfers it to transfermodule 410 d, which then delivers the workpiece 200 into first etchingmodule 430. Adjustments to the controlled environment may be made intransfer modules 410 c and 410 d if first etching module 430 operateswith different parameters than film-forming module 420, such asdifferent vacuum pressures. The workpiece 200 is etched in the firstetching module 430 a to remove the film nuclei 260 from upper surfacesof the SAM 240. Although the layer of dielectric additive material 250may also be partially removed by the etching process, the film nuclei260 are expected to etch faster than etching of the layer of dielectricadditive material 250. The etching process can include a dry etchingprocess, a wet etching process, or a combination thereof.

Transfer modules 410 d and 410 e are then used to transfer the workpiece200 to a second etching module 430 hosted on the common manufacturingplatform 400, and the workpiece 200 is etched to remove the SAM 240.Again, the common manufacturing platform 400 may include identical firstetching modules 430 on opposing sides of the transfer modules 410 d and410 e. Alternatively, the SAM 240 may be removed by a different method,such as by heat treatment, in a designated treatment module or in one ofthe processing modules used in another step of the integrated sequenceof processing steps.

If a target thickness for the layer of dielectric additive material 250has not been reached, as determined in operation 310, theabove-described integrated sequence of processing steps 304—308, may berepeated, in whole or in part, one or more times to increase thethickness of the layer of dielectric additive material 250 on theworkpiece 200, as schematically shown by process arrow 312. Removal andsubsequent repeated deposition of the SAM 240 on the workpiece 200 maybe desired if the SAM 240 becomes damaged during the additive materialdeposition and/or the etching process to remove the film nuclei 260.However, if the SAM 240 has not been compromised, its removal andreapplication may be omitted in the repetition of the additive materialdeposition and film nuclei etch.

Upon completion of process flow 300, i.e., when the determination inoperation 310 indicates the target thickness has been reached, theworkpiece 200 exits the common manufacturing platform 400 via anotherfront-end module 402 b, which may be identical to front-end module 402a, although located at the back end of the end-to-end arrangement ofmodules on common manufacturing platform 400. In the generally reverseprocess of front-end module 402 a, the workpieces 100 are sequentiallytransferred by transfer module 410 e to a load lock where the controlledenvironment is removed and then into a cassette (not shown) on thefront-end module 402 b. The common manufacturing platform 400 arrangedin a substantially mirrored fashion has the advantage of providingredundancy in the event a module has to go out of service, where thecommon manufacturing platform 400 could still operate at a reducedcapacity.

In one embodiment, and as will be discussed in more detail below, thecommon manufacturing platform 400 advantageously includes an “activeinterdiction system.” The active interdiction system includes aworkpiece measurement region within a transfer module 410 hosted on thecommon manufacturing platform 400 or an integrated metrology module (notshown) hosted on the common manufacturing platform 400. The workpiecemeasurement region may be located in a dedicated area of the transfermodule 410, as described in more detail below. The workpiece measurementregion or metrology module may include an inspection system forgathering measurement data. As described in more detail below, theinspection system may include at least one optical source for directingan optical beam incident on a measurement surface of the workpiece andat least one detector arranged to receive an optical signal scatteredfrom the measurement surface of the workpiece. The active interdictionsystem may further include an intelligence system hosted on the commonmanufacturing platform 400 that is configured to gather data from theworkpiece measurement region or metrology module and control theintegrated sequence of processing steps executed on the commonmanufacturing platform 400, such as process flow 300.

For active interdiction in accordance with embodiments of the invention,the workpiece measurement region or metrology module collects real timedata “on the fly” pertaining to attributes of features or layers on thesemiconductor workpiece (e.g., film or feature thickness, feature depth,surface roughness, pattern shift, voids or other defects, loss ofselectivity, lateral overgrowth, uniformity, etc.) and uses such realtime data to concurrently control integration operating variables in theintegrated processing modules hosted on the common manufacturingplatform 400. The data can be used in a feed-back and/or feed-forwardmanner to control operations performed on the workpiece in subsequentmodules and/or to control operations performed in prior modules on asubsequent workpiece, for example as will be explained below withreference to operations 320-326 of FIG. 3. In an embodiment, the commonmanufacturing platform 400 includes a correction module, which may be afilm-forming module 420, an etching module 430, a pre-treatment module415, or other type of treatment module as appropriate for applyingcorrective action or remedial treatment to the workpiece 200.

Unlike traditional metrology or process control, the workpiece does notleave the controlled environment to enter a stand-alone metrology toolthereby minimizing oxidation and defect generation, the measurements arenon-destructive such that no workpiece is sacrificed to obtain datathereby maximizing production output, and the data can be collected inreal time as part of the process flow to avoid negatively impactingproduction time and to enable in-process adjustments to the workpiece orto subsequent workpieces being sequentially processed on the commonmanufacturing platform 400. Additionally, the measurements are notperformed in the film-forming or etching modules, thereby avoidingissues when measurement devices are exposed to process fluids. Forexample, by incorporating workpiece measurement regions into thetransfer module, the data can be obtained as the workpiece is travelingbetween processing tools with little to no delay in the process flow,without exposure to process fluids, and without leaving the controlledenvironment, e.g., without breaking vacuum. While the “on the fly” datamay not be as accurate as the data obtained from traditional destructivemethods performed in stand-alone metrology tools, the nearlyinstantaneous feedback on the process flow and ability to make real-timeadjustment without interrupting the process flow or sacrificing yield ishighly beneficial for high-volume manufacturing.

With further reference to the process flow 300 of FIG. 3, the method mayinclude inspecting the workpiece, such as performing metrology, i.e.,obtaining measurement data, using the active interdiction system at anyof various times throughout the integrated method, without leaving thecontrolled environment, e.g., without breaking vacuum. Inspection of theworkpiece may include characterizing one or more attributes of theworkpiece and determining whether the attribute meets a targetcondition. For example, the inspection may include obtaining measurementdata related to an attribute and determining whether a defectivity,thickness, uniformity, and/or selectivity condition meets a target forthat condition. While the following discussion will focus on obtainingmeasurement data, it may be understood that other inspection techniquesperformed within the controlled environment of the common manufacturingplatform are also within the scope of the invention.

The active interdiction system may include a single metrology module orworkpiece measurement region on the common manufacturing platform 400 ormay include multiple metrology modules or workpiece measurement regionson the common manufacturing platform 400, as will be discussed in moredetail below. Each metrology operation is optional, as indicated by thephantom lines in FIG. 3, but may be advantageously performed at one ormore points in the process flow to ensure the workpiece 200 is withinspecification. In one embodiment, measurement data is obtained aftereach step of the integrated sequence of processing steps conducted onthe common manufacturing platform. The measurement data may be used torepair the workpiece in a correction module prior to leaving the commonmanufacturing platform, and/or may be used to alter parameters of theintegrated sequence of processing steps for subsequent steps and/or forsubsequent workpieces.

In broad terms, within the controlled environment, measurement data maybe obtained during the integrated sequence of processing steps relatedto the selective deposition of the additive material and, based on themeasurement data, a determination may be made whether defectivity,thickness, uniformity, and/or selectivity of the layer of additivematerial meets a target condition. When the defectivity, thickness,uniformity, and/or selectivity is determined to not meet the targetcondition, or an attribute of the workpiece is otherwise determined tobe non-conforming, the workpiece may be subjected to further processing.For example, the workpiece may be processed in a correction module onthe common manufacturing platform to remove, minimize, or compensate forthe non-conforming attribute prior to performing a next processing stepin the integrated sequence of processing steps. The corrective actionmay include etching the target surface or non-target surface, depositingfurther additive material on the workpiece, repairing a barrier layer onthe workpiece, thermally treating the workpiece, or plasma treating theworkpiece.

In one example, the corrective action may include removing the SAM whenthe non-conformity is based, at least in part, on incomplete coverage ofthe non-target surface by the SAM or when an amount of exposed area ofthe non-target surface is greater than a predetermined exposed areathreshold. In another example, the corrective action may includeremoving at least a portion of the layer of additive material when thenon-conformity is based, at least in part, on a step-height distancebetween the target surface and the non-target surface being less than apredetermined step-height threshold or an amount of exposed area of thenon-target surface being less than the predetermined exposed areathreshold. In yet another example, the corrective action may includeadding further additive material to the workpiece when thenon-conformity is based, at least in part, on a thickness of theadditive material overlying the target surface being less than apredetermined thickness threshold. In a still further example, thecorrective action may include etching the workpiece when thenon-conformity is based, at least in part, on a remaining additivematerial on the non-target surface or a remaining self-assembledmonolayer on the non-target surface being greater than a predeterminedremaining thickness threshold. In another example, the corrective actionmay include thermally treating or plasma treating the workpiece when thenon-conforming workpiece attribute is based, at least in part, on areflectivity from the workpiece being less than a predeterminedreflectivity threshold.

The correction modules may be different film-forming and etching modulesthat are designated as correction modules on the common manufacturingplatform or another type of treatment module integrated on the commonmanufacturing platform, such as a thermal annealing module, or may bethe same film-forming and etching modules used to selectively depositthe additive material and etch the film nuclei.

The process flow 300 of FIG. 3 will now be described in detail with theoptional inspection or metrology operations used to characterizeattributes of the workpiece to determine when a target thickness for theASD is reached and/or to determine if a non-conformality is present.Operation 302 includes receiving a workpiece having the target andnon-target surfaces into a common manufacturing platform. Operation 320includes optionally performing metrology to obtain measurement datarelated to attributes of the incoming workpiece, such as attributes ofthe target surface and/or the non-target surface, which measurement datamay be used to adjust and/or control process parameters of any one ofoperations 304-308.

Operation 304 includes optionally pre-treating the workpiece. Thepre-treatment may be a single operation or multiple operations executedon the common manufacturing platform. Operation 322 includes optionallyperforming metrology to obtain measurement data related to attributes ofthe workpiece following the pre-treatment. If multiple pre-treatmentoperations are performed, the measurement data may be obtained after allpre-treatments are completed and/or after any individual pre-treatmentstep. In one example, the workpiece is inspected after a SAM is formedto determine whether the coverage is complete or if an exposed area ofthe treated surface exceeds a threshold value. The measurement data maybe used to adjust and/or control process parameters of any one ofoperations 306-308, may be used to make adjustments for subsequentworkpieces to the incoming attributes of the workpieces in operation 302or to operation 304, or may be used to repair the workpiece beforecontinued processing. In one embodiment, when the measurement dataindicates that one or more attributes do not meet a target condition,the workpiece may be transferred to a correction module to repair theworkpiece. For example, when coverage by a SAM on the non-target surfaceis incomplete, corrective action may be taken in one or more correctionmodules, such as removing the SAM and reapplying the SAM.

Operation 306 includes selectively depositing additive material on theworkpiece in a film-forming module hosted on the common manufacturingplatform. Operation 324 includes optionally performing metrology toobtain measurement data related to attributes of the workpiece havingthe layer of additive material formed on the target surface, such asattributes of the layer of additive material, the non-target surface,and/or a pre-treated surface as affected by the selective deposition,which measurement data may be used to adjust and/or control processparameters of any one of operations 308-312, may be used to makeadjustments for subsequent workpieces to the incoming attributes of theworkpieces in operation 302 or to operations 304-306, or may be used torepair the workpiece before continued processing. In one embodiment,when the measurement data indicates that one or more attributes do notmeet a target condition, the workpiece may be transferred to acorrection module to repair the layer of additive material or thenon-target surface. For example, when the defectivity, thickness,uniformity, or selectivity of the additive material does not meet atarget condition, corrective action may be taken in one or morecorrection modules, such as by selectively depositing additionaladditive material onto the target surface, removing additive materialfrom the non-target surface or target surface, removing a pre-treatmentlayer from the non-target surface, thermally treating or plasma treatingthe workpiece, or a combination of two or more thereof.

Operation 308 includes etching the workpiece using an etching modulehosted on the common manufacturing platform to expose the non-targetsurface. Operation 308 may include etching film nuclei that deposited onthe non-target surface or on a SAM formed on the non-target surface oretching a complete layer of additive material deposited on thenon-target surface or on a SAM formed on the non-target surface at athickness less than the thickness of the layer of additive materialformed on the target surface. Operation 308 may also include removing aSAM or other pre-treatment layer from the non-target surface, either inthe same etching step or a subsequent etching step. Operation 326includes optionally performing metrology to obtain measurement datarelated to attributes of the workpiece having the layer of additivematerial on the target surface and the etched non-target surface, suchas attributes of the layer of additive material as affected by theetching, attributes of the non-target surface exposed by the etching,and/or attributes of a SAM or other pre-treatment layer as affected byetching the film nuclei from the SAM on the non-target surface, whichmeasurement data may be used to adjust and/or control process parametersof any one of operations 310-312, including steps 304-308 in therepetition of the sequence per operation 312, may be used to makeadjustments for subsequent workpieces to the incoming attributes of theworkpieces in operation 302 or to operations 304-308, or may be used torepair the workpiece before continued processing. In one embodiment,when the measurement data indicates that one or more attributes do notmeet a target condition, the workpiece may be transferred to acorrection module to the layer of additive material or the non-targetsurface. For example, when the defectivity, thickness, uniformity, orselectivity of the additive material does not meet a target condition,corrective action may be taken in one or more correction modules, suchas by selectively depositing additional additive material onto thetarget surface, removing additive material from the non-target surfaceor target surface, removing a pre-treatment layer from the non-targetsurface, thermally treating or plasma treating the workpiece, or acombination of two or more thereof. Further, when the measurement dataindicates that the thickness of the layer of additive material is lessthan a target thickness, such that determination 310 is No, theworkpiece may be subjected to repeating steps of the sequence peroperation 312. When the measurement data indicates that the thickness ofthe layer of additive material has reached the target thickness, suchthat determination 310 is Yes, the workpiece may exit the commonmanufacturing platform.

Process parameters, as referred to above, may include any operatingvariable within a processing module, such as but not limited to: gasflow rates; compositions of etchants, deposition reactants, purge gases,etc.; chamber pressure; temperature; electrode spacing; power; etc. Theintelligence system of the active interdiction system is configured togather measurement data from the inspection system and control theintegrated sequence of processing steps executed on the commonmanufacturing platform, for example, by making in situ adjustments toprocessing parameters in subsequent processing modules for the workpiecein process, or by changing process parameters in one or more processingmodules for subsequent workpieces. Thus, the obtained measurement datamay be used to identify a needed repair to the workpiece during theintegrated sequence of processing steps to avoid having to scrap theworkpiece, and/or to adjust processing parameters for the integratedsequence of processing steps for steps performed on the same workpieceafter the measurement data is obtained or for processing subsequentworkpieces to reduce occurrences of the target conditions not being metfor the subsequent workpieces.

With further reference to FIG. 4, the common manufacturing platform 400generally includes at least one front-end module 402, for example one ateach end of the common manufacturing platform 400 as shown fortransferring workpieces 100 into and out of the common manufacturingplatform 400. Common manufacturing platform 400 includes a plurality oftransfer modules 410 for transferring workpieces into and out of aplurality of processing modules hosted on the common manufacturingplatform 400. The plurality of processing modules includes one or morefilm-forming modules 420, such as one or more deposition tools, and oneor more etching modules 430, such as one or more dry etching tools, wetetching tools and/or COR tools. Optionally, the plurality of processingmodules further includes one or more pre-treatment modules 415, whichmay be film-forming modules, etching modules or other type of processingmodule. The pre-treatment modules 415 may be used to perform operation304. The film-forming modules 420 may be used to perform operation 306.The etching modules 430 may be used to perform operation 308. Any of theprocessing modules may serve as a correction module for repairing theworkpiece, or additional processing modules may be added for performingcorrective action. As shown, the plurality of processing modulesgenerally forms two lines 440, 450 from front end to back end, one line440 down one side of a row of transfer modules 410 and the other line450 down the other side of the row of transfer modules 410.

In one example, a single workpiece 100 is processed down line 440 fromfront end to back end, then transferred back to the front end andprocessed again down line 450. Thus, the pre-treatment operation 304,selective deposition operation 306, and etch operation 308 are performeddown line 440 to deposit an initial thickness of additive material, thenthe pre-treatment operation 304, selective deposition operation 306, andetch operation 308 are performed down line 450 to further increase theadditive material thickness, thereby repeating the operations in twopasses down the end-to-end common manufacturing platform 400.

In another example, the two lines 440, 450 operate independently toprocess two workpieces 200 concurrently, either temporally in-phase ortemporally off-set, each progressing down one of the lines 440 or 450from front end to back end, then transferred back to the front end andeach processed again down the same line 440 or 450 for additionalrepetitions. Thus, the pre-treatment operation 304, selective depositionoperation 306, and etch operation 308 are performed down each line 440and 450 to deposit the initial thickness of additive material, then thepre-treatment operation 304, selective deposition operation 306, andetch operation 308 are repeated down the same lines 440 and 450 tofurther increase the additive material thickness, thereby repeating theoperations in two or more passes down the end-to-end commonmanufacturing platform 400. This example has the advantage of providingredundancy in the event a module has to go out of service, where thecommon manufacturing platform 400 can still operate at 50% capacity.

A cleaning etch or repair process can be performed at the end of thefirst or a subsequent pass before transferring the workpiece 200 back tothe front end in order to clean or repair the workpiece before repeatingthe operations or before exiting the common manufacturing platform 400.A correction module may be added in the lines 440, 450 for performingrepairs.

In one embodiment, the common manufacturing platform includes at leastone deposition module for selectively depositing additive material on atarget surface, at least one etching module for removing additivematerial from a non-target surface to achieve selectivity, and at leastone transfer module for transferring the workpiece between modules whilemaintaining a controlled environment throughout the integrated processflow. Advantageously, a pre-treatment module is included for forming aSAM on the non-target surface as a barrier layer to increase selectivitytoward the target surface, and the at least one etching module includesat least two etching modules, one for removing additive material fromthe SAM and one for removing the SAM. In a further embodiment, thecommon manufacturing platform includes at least one workpiecemeasurement region, which is located within a dedicated area of the atleast one transfer module or within a metrology module hosted on thecommon manufacturing platform within the controlled environment, forobtaining measurement data related to one or more attributes of theworkpiece. In one embodiment, the common manufacturing platform includesat least one correction module for performing a repair of the workpiece,such as repairing the selectively deposited additive material orrepairing a SAM.

As may be appreciated by persons having ordinary skill in the art, thenumber and positioning of processing modules on the common manufacturingplatform as well as metrology operations may be selected based on theprocessing time in the different modules needed to carry out theoperations in the different modules to provide essentially continuousprocess flow through the common manufacturing platform and thus goodthroughput matching.

FIGS. 5A-5D illustrate another embodiment of an area-selectivedeposition (ASD) method for a workpiece, which method may also beperformed according to the process flow 300 of FIG. 3 executed on thecommon manufacturing platform 400 of FIG. 4. The workpiece 500 includesa target surface 520 of a first material and a non-target surface 530 ofa second material different than the first material on substrate 510.The target and non-target surfaces 520, 530 may form a planar surface,as shown, similar to FIGS. 1A and 1C, or may have an initial step-heightdifference, similar to FIGS. 1B and 1D. The workpiece 500 may thus haveany pattern formed thereon comprising at least first and seconddissimilar materials with at least one target surface 520 of the firstmaterial exposed upon which deposition is desired, and at least onenon-target surface 530 of the second material exposed upon whichdeposition is not desired. In the embodiment depicted in FIGS. 5A-5D,the first material is a metal such that the target surface 520 is atarget metal surface, and the second material is a dielectric materialsuch that the non-target surface 530 is a non-target dielectric surface.The additive material to be deposited on the target metal surface 520may be the same or different metal as the first metal or may be adielectric material.

Referring to FIGS. 3 and 4, in optional operation 304, in the firstpre-treatment module 415, a first pre-treatment process is performed toexpose the workpiece 200 to a treatment gas. For example, the treatmentgas can include an oxidizing gas or a reducing gas. In some examples,the oxidizing gas can include O₂, H₂O, H₂O₂, isopropyl alcohol, or acombination thereof, and the reducing gas can include H₂ gas. In oneexample, the treatment gas can include or consist of plasma-excited Argas. The treatment gas can clean or alter the surface of either thetarget metal surface 520 or the non-target dielectric surface 530 toimprove subsequent ASD. For ASD on a metal surface, a de-oxidizingtreatment of the target metal surface 520 may be desired.

Referring to FIGS. 5B, 3 and 4, and further in optional operation 304,without leaving the controlled environment, e.g., without breakingvacuum, a second pre-treatment process is performed to render thenon-target dielectric surface 530 less attractive or reactive to theadditive material to be deposited on the target metal surface 520. Asshown, the pre-treatment may include a barrier layer 540 beingselectively deposited over the non-target dielectric surface 530 toinhibit deposition of the additive material thereon and to increase theselectivity toward the target metal surface 520. The barrier layer 540may be a SAM or any other surface treatment layer that has the effect ofinhibiting deposition of the additive material on the treated surface.

Then, without leaving the controlled environment, e.g., without breakingvacuum, and referring to FIGS. 5C and 3, in operation 306, in thefilm-forming module 420, metal additive material 550 is selectivelydeposited on the target metal surface 520 to form an elevated metalpattern. Due to the selectivity toward the target metal surface 520relative to the SAM 540 on the non-target dielectric surface 530, alayer of the metal additive material 550 forms on the target metalsurface 520 at a higher deposition rate than on the non-targetdielectric surface 530.

As depicted in FIG. 5C, the exposure to deposition gases in film-formingmodule 420 may, in addition to depositing the metal additive material550 on the target metal surface 520, deposit film nuclei 560 on the SAM540 as a result of a loss of selectivity or insufficient selectivity.Loss of deposition selectivity can occur, for example, if the depositionprocess is carried out for too long. Insufficient or poor depositionselectivity can occur, for example, if surface coverage of the SAM 540is incomplete and contains voids on the non-target dielectric surface530.

Referring to FIGS. 5D and 3, in operation 308, and without leaving thecontrolled environment, e.g., without breaking vacuum, the workpiece 500is transferred to one or more etching modules to perform one or moreetching steps to expose the non-target dielectric surface 530 andthereby achieve the ASD on the target metal surface 520. In thisexample, two etching steps are performed sequentially to first removethe film nuclei 560 and then remove the SAM 540. The workpiece 500 isetched in the first etching module 430 to remove the film nuclei 560from upper surfaces of the SAM 540. Although the layer of metal additivematerial 550 may also be partially removed by the etching process, thefilm nuclei 560 are expected to etch faster than etching of the layer ofmetal additive material 550. The etching process can include a dryetching process, a wet etching process, or a combination thereof.

In a second etching module 430 hosted on the common manufacturingplatform 400, the workpiece 500 is etched to remove the SAM 540.Alternatively, the SAM 540 may be removed by a different method, such asby heat treatment, in a designated treatment module or in one of theprocessing modules used in another step of the integrated sequence ofprocessing steps.

If a target thickness for the layer of metal additive material 550 hasnot been reached, as determined in operation 310, the above-describedintegrated sequence of processing steps 304-308, may be repeated, inwhole or in part, one or more times to increase the thickness of thelayer of metal additive material 550 on the workpiece 500, asschematically shown by process arrow 312. Removal and subsequentrepeated deposition of the SAM 540 on the workpiece 500 may be desiredif the SAM 540 becomes damaged during the additive material depositionand/or the etching process to remove the film nuclei 560. However, ifthe SAM 540 has not been compromised, its removal and reapplication maybe omitted in the repetition of the additive material deposition andfilm nuclei etch. Upon completion of process flow 300, i.e., when thedetermination in operation 310 indicates the target thickness has beenreached, the workpiece 500 exits the common manufacturing platform 400.The same optional metrology steps 320-326 as described above may also beperformed in the embodiment of FIGS. 5A-5D.

In accordance with an embodiment, within the controlled environment,measurement data may be obtained related to one or more attributes ofthe workpiece and, based on the measurement data, a determination may bemade whether a defectivity, thickness, uniformity, and/or selectivity ofthe additive material on the workpiece meets a target condition. Whenthe target condition is not met, the workpiece may be processed in acorrection module to remove at least a portion of the additive materialfrom the target surface and/or the non-target surface, or to performother corrective action. When the measurement data indicates anattribute is non-conforming, the corrective action may remove, minimize,or compensate for the non-conforming attribute prior to performing anext processing step in the integrated sequence of processing steps.

At least one of the transfer modules may include a workpiece measurementregion located within a dedicated area thereof for obtaining themeasurement data, and the data may be obtained during at least one ofthe transfers of the workpiece between the plurality of processingmodules by passing the workpiece into the workpiece measurement region.Alternatively or additionally, the common manufacturing platform mayinclude one or more metrology modules, and the data is obtained bytransferring the workpiece into the metrology module before, between orafter one or more of the processing steps of the integrated sequence ofprocessing steps.

The one or more attributes to which the obtained measurement data mayrelate include attributes of the target surface prior to depositing theadditive material, attributes of the non-target surface prior todepositing the additive material, attributes of the layer of additivematerial after depositing the additive material, attributes of thenon-target surface after depositing the additive material, attributes ofthe layer of additive material after etching the workpiece, orattributes of the non-target surface after etching the workpiece.Further, the one or more attributes may include an amount of voids onthe target surface, an amount of additive material on the non-targetsurface, a loss of selectivity, a profile of the additive material, anamount of the additive material on one region of the workpiece relativeto an amount of the additive material on another region of theworkpiece, or a combination of two or more thereof.

In an embodiment, corrective action to address a non-conformingattribute may include removing the self-assembled monolayer when thenon-conforming attribute is based, at least in part, on incompletecoverage of the non-target surface by the self-assembled monolayer or anamount of exposed area of the non-target surface being greater than apredetermined exposed area threshold. In another embodiment, correctiveaction to address a non-conforming attribute may include removing atleast a portion of the layer of additive material when thenon-conforming attribute is based, at least in part, on a step-heightdistance between the target surface and the non-target surface beingless than a predetermined step-height threshold or an amount of exposedarea of the non-target surface being less than the predetermined exposedarea threshold. In another embodiment, corrective action to address anon-conforming attribute may include adding further additive material tothe workpiece when the non-conforming attribute is based, at least inpart, on a thickness of the additive material overlying the targetsurface being less than a predetermined thickness threshold. In anotherembodiment, corrective action to address a non-conforming attribute mayinclude etching the workpiece when the non-conforming attribute isbased, at least in part, on a remaining additive material on thenon-target surface or a remaining self-assembled monolayer on thenon-target surface being greater than a predetermined remainingthickness threshold. In yet another embodiment, corrective action toaddress a non-conforming attribute may include treating the workpiecewhen the non-conforming workpiece attribute is based, at least in part,on a reflectivity from the workpiece being less than a predeterminedreflectivity threshold, wherein the treating is a temperature treatment,a plasma etch treatment, or combination thereof.

As disclosed herein the term “metrology module” or “measurement module”refers to a module/system/sensor/tool that can make measurements on aworkpiece to detect or determine various non-conformities or variationson the workpiece, such as parametric variations, or to detect ordetermine defects on the workpiece, such as a contamination of somekind. As used herein, the term “inspection system” will generally referto the tool or system of a measurement process or module that measuresand collects data or signals associated with the measurement. Themeasurement modules will make measurements and provide data for use inthe processing platform as disclosed further herein. The terms“metrology module” and “measurement module” will be used interchangeablyherein, and generally refer to measurement or metrology or sensing toolsused to detect and measure attributes of a workpiece that are indicativeof the processing of the workpiece and the layers and devices beingformed thereon.

To move workpieces between the various processing modules, the commonmanufacturing platform will generally incorporate one or more workpiecetransfer modules that are hosted on the common manufacturing platformand are configured for the movement of the workpiece between theprocessing modules and the measurement module(s). A measurement modulemight be coupled with the workpiece transfer module similar to aprocessing module. In some embodiments of the invention, as disclosedherein, a measurement module or the inspection system associatedtherewith is incorporated with or inside a transfer module to providefor measurement or metrology as the workpiece is moved betweenprocessing modules. For example, a measurement module, or a portionthereof, might be positioned inside an internal space of the transfermodule. Herein, the combination transfer and measurement apparatus willbe referred to as a transfer measurement module (“TMM”).

In one embodiment, the common manufacturing platform including bothprocessing chambers and measurement modules is actively controlled by asystem that processes the measured data associated with an attribute onthe workpiece and uses the measured data for controlling movement andprocessing of the workpiece in a processing sequence. In accordance withembodiments of the invention, the control system uses measured data andother data to perform corrective processing based in part on themeasured data to provide active interdiction of the processing sequenceto correct non-conformities or defects. More specifically, an activeinterdiction control system is hosted on the common manufacturingplatform and is configured to perform corrective processing based inpart on the measured data, wherein the corrective processing of theworkpiece might be performed in the processing modules of the platformthat are upstream or downstream in the process sequence to addresssituations where non-conformities or defects are detected. In anembodiment of the invention, the workpiece is maintained in a controlledenvironment, such as under vacuum, for example. That is, on the commonmanufacturing platform, the processing modules and the measurementmodule operate in a controlled environment, and the workpiece transfermodule transfers the workpiece between the plurality of processingmodules in the processing sequence and one or more measurement moduleswithout leaving the controlled environment.

As used herein, the term “active interdiction” refers generally to thecontrol system as implemented for capturing measurement/metrology datain real time with respect to various fabrication processes to obtaindata on workpiece attributes and thereby detect non-conformities ordefects and the corrective aspects of the control to correct orameliorate the non-conformities or defects. The active interdictioncontrol system uses the data for correction and amelioration of variousnon-conformities in the semiconductor fabrication process by activelyvarying the processing sequence and/or the operation of modules thatperform process steps. Thus, the active interdiction control system alsointerfaces with one or more transfer modules (e.g., 410) used to moveworkpieces through the process. The active interdiction control system(622 in FIGS. 6 and 722 in FIGS. 7A-7D, as further described below)coordinates the data collection and data analysis and detection ofnon-conformities with the fabrication process and further directs theactions of multiple processing modules so as to address thenon-conformities or defects that are detected. The active interdictioncontrol system is implemented generally by one or more computer orcomputing devices as described herein that operate a specially designedsets of programs such as deep learning programs or autonomous learningcomponents referred to collectively herein as active interdictioncomponents. As may be appreciated, the active interdiction controlsystem may incorporate multiple programs/components to coordinate thedata collection from various measurement modules and the subsequentanalysis. The active interdiction control system interfaces with themultiple processing modules in the common manufacturing platform inorder to address various measured non-conformities/defects to correct orameliorate the non-conformities/defects. The active interdiction controlsystem will thereby control one or more of the processing modules andthe processing sequence to achieve the desired results of the invention,which may be referred to as the target conditions or predeterminedthresholds.

The active interdiction control system also controls the transfermodules in order to move the workpieces to upstream and/or downstreamprocessing modules when non-conformities/defects are detected. That is,depending upon what is detected, the system of the invention may movethe workpiece further along in the processing sequence, or may directthe workpiece to a correction module or to an upstream processing moduleto correct or otherwise address a detected non-conformity or defect. Assuch, feedforward and feedback mechanisms are provided through thetransfer modules to provide the active interdiction of the invention.Furthermore, the processing sequence might be affected upstream ordownstream for future workpieces.

The active interdiction features of the invention improve performance,yield, throughput, and flexibility of the manufacturing process usingrun-to-run, wafer-to-wafer, within the wafer and real-time processcontrol using collected measurement/metrology data. The measured data iscollected, in real time during the processing, without removing theworkpiece/substrate/wafer from the controlled processing environment. Inaccordance with one feature of the invention, in a common manufacturingplatform, the measurement data may be captured while the substrateremains in a controlled environment, such as under vacuum, for example.That is, the workpiece transfer module(s) are configured fortransferring the workpiece between the plurality of processing modulesand the measurement modules without leaving the controlled environment.The active interdiction control can provide a multivariate, model-basedsystem that is developed in conjunction with feed-forward and feedbackmechanisms to automatically determine the optimal recipe for eachworkpiece based on both incoming workpieces and module or tool stateproperties. The active interdiction control system uses fabricationmeasurement data, process models and sophisticated control algorithms toprovide dynamic fine-tuning of intermediate process targets that enhancefinal device targets. The interdiction system enables scalable controlsolutions across a single chamber, a process tool, multi-tools, aprocess module and multi-process modules on a common manufacturingplatform using similar building blocks, concepts, and algorithms asdescribed herein.

FIG. 6 is a schematic diagram of another system for implementing anembodiment of the present invention on a common manufacturing platform600. The platform 600 incorporates a plurality of processingmodules/systems for performing integrated workpiece processing andworkpiece measurement/metrology under the control of an activeinterdiction control system 622 according to embodiments of theinvention. FIG. 6 illustrates an embodiment of the invention wherein oneor more workpiece measurement modules are coupled together with one ormore workpiece processing modules through one or more transfer modules.In that way, in accordance with features of the invention, an inspectionof the workpiece may be made to provide the measurement data associatedwith an attribute of the workpiece, such as regarding materialproperties of the workpiece and the various thin films, layers andfeatures that are formed on the workpiece while the workpiece remainswithin the common manufacturing platform. As discussed herein,measurements and analysis may be made immediately upon completion ofprocessing steps, such as an etch or deposition step, and themeasurement data gathered may be analyzed and then used within thecommon manufacturing platform to address any measurements or featuresthat are out of specification or non-conformal or represent a defectwith respect to the workpiece design parameters. The workpiece does notneed to be removed from the common manufacturing platform to takecorrective action, but rather, can remain under the controlledenvironment.

Referring to FIG. 6, common manufacturing platform 600 isdiagrammatically illustrated. Platform 600 includes a front-end module602 for introducing one or more workpieces into the manufacturingplatform. As is known, the front-end module (FEM) may incorporate one ormore cassettes holding the workpieces. The front-end module may bemaintained at atmospheric pressure but purged with an inert gas toprovide a clean environment. One or more workpieces may then betransferred into a transfer module 610, such as through one or moreload-lock chambers (not shown) as discussed herein. The transfer modulesof FIG. 6 are transfer measurement modules (TMM) that includemeasurement tools or inspection systems integrated therein for capturingdata from a workpiece. Multiple TMM's 610 may be interfaced forproviding movement of a workpiece through a desired sequence. Thetransfer measurement modules 610 are coupled with a plurality ofprocessing modules. Such processing modules may provide variousdifferent processing steps or functions and may include one or more etchmodules 630, one or more film-forming modules 620, one or more cleaningmodules 640, and one or more measurement modules 612 a, 612 b, 612 c,612 d. In accordance with embodiments of the invention as disclosedfurther herein, measurement modules may be accessed through the transfermodules 610 before or after each processing step. In one embodiment, themeasurement modules, such as 612 c, 612 d, are located outside of thetransfer modules 610 and are accessed to insert and receive workpiecessimilar to the various processing modules and may be referred to hereinas metrology modules that reside within the controlled environment ofthe common manufacturing platform 600. Alternatively, measurementmodules or at least a portion thereof, such as modules 612 a, 612 b, maybe located in a respective transfer module. More specifically, all or aportion of a measurement module 612 a, 612 b is located in a transfermodule 610 to define a measurement region therein where a workpiecemight be positioned for measurement during a transfer process. Themeasurement region is located in a dedicated area of the transfer module610 and is accessible by the transfer mechanism of the transfer modulefor positioning the workpiece. As noted, this makes the transfer moduleessentially a transfer measurement module (TMM) as discussed herein.

Generally, the transfer module defines a chamber therein that houses atransfer robot that is capable of moving workpieces, under vacuum,through various gate valves and access or transfer ports into variousprocessing modules or measurement modules. By maintaining themeasurement modules on the common manufacturing platform 600, they arereadily accessed, such as between one or more of the processing steps toprovide the necessary measured analytical data on-the-fly that will beused to address any workpiece out of specification or otherwisenon-conformal with the workpiece design plans for a particular workpieceor to address detectable defects. In that way, real time data isprovided to allow a fabricator to recognize problems early in the systemso that remedial action may be taken in the current processing sequence,such as in a following processing step, in a previous processing step,and/or in a future processing step depending upon the captured data andthe detected non-conformities or defects. In that way, productivity andefficiency may be increased, process monitoring overhead may be reduced,and wasted product, in the form of rejected or ejected workpieces may bereduced. This all provides a significant cost savings to a fabricator ordevice maker.

As noted, in one embodiment of the invention that incorporates theactive interdiction control system 622, one or more measurement modulesare hosted on a common manufacturing platform with processing modulesfor providing measured data regarding an attribute of the workpiece. Thedata is used by the active interdiction control system 622 for detectingnon-conformities and for performing corrective processing of theworkpiece when non-conformities are detected. The corrective processingis performed upstream and/or downstream in the process sequence whennon-conformities are detected.

Referring to FIG. 7A, an exemplary common manufacturing platform 700suitable for practicing a method of ASD is illustrated. The commonmanufacturing platform 700 incorporates multiple modules and processingtools for the processing of semiconductor substrates for the fabricationof integrated circuits and other devices. The common manufacturingplatform 700 incorporates one or more metrology/measurement modules thatare incorporated within the common manufacturing platform 700 along withthe processing modules. For example, the platform 700 may incorporate aplurality of processing modules that are coupled to a transfer module asshown. In some embodiments, a measurement module or tool is alsopositioned, at least partially, inside the transfer module. As such, aworkpiece may be processed and then transferred immediately to ameasurement module in order to collect various fabrication dataassociated with attributes of the workpiece that is further processed bythe active interdiction control system. The active interdiction controlsystem gathers data from the processing and measurement modules andcontrols a process sequence that is executed on the common manufacturingplatform through the selective movement of the workpiece and control ofone or more of the plurality of processing modules. Furthermore, theprocessing system of platform 700 may transfer a workpiece inside thechamber of the transfer module and between the various processingmodules and the measurement/metrology modules without leaving thecontrolled environment of the common manufacturing platform 700. Theactive interdiction control system controls the sequential process flowthrough the various processing modules utilizing information that isderived from workpiece measurements obtained from the one or moremeasurement modules. Furthermore, the active interdiction control systemincorporates processing modules in-situ measurements and data to controlthe sequential process flow through the platform 700. The on-substratemeasurement data obtained in the controlled environment may be utilizedalone or in combination with the in-situ processing module measurementdata for process flow control and improvement of the process inaccordance with the invention.

Turning again to FIG. 7A, common manufacturing platform 700 contains afront-end module 702 to introduce workpieces into the controlledenvironment. The exemplary platform 700 includes a plurality ofprocessing modules 720 a-720 d and one or more measurement/metrologymodules 716 organized around the periphery of a workpiece transfermodule 710. Common manufacturing platform 700 includes cassette modules704 and load-lock chambers 708 coupled to front-end module 702. Thefront-end module 702 is generally maintained at atmospheric pressure,but a clean environment may be provided by purging with an inert gas.Load-lock chambers 708 are coupled to the centralized workpiece transfermodule 710 and may be used for transferring workpieces from thefront-end module 702 to the workpiece transfer module 710 for processingin the controlled environment of the platform 700.

The workpiece transfer module 710 may be maintained at a very low basepressure (e.g., 5×10−8 Torr, or lower) or constantly purged with aninert gas. In accordance with the invention, a measurement/metrologymodule 716 may be operated under atmospheric pressure or operated undervacuum conditions. In accordance with one embodiment, the measurementmodule 716 is kept at vacuum conditions and the wafer is processed inplatform 700 and measured without leaving vacuum. As disclosed furtherherein, the metrology module may include one or more inspection systemsor analytical tools that are capable of measuring one or more materialproperties or attributes of a workpiece and/or of the thin films andlayers deposited on the workpiece or the devices formed on theworkpiece. As used herein, the term “attribute” is used to indicate ameasurable feature or property of a workpiece, layer on a workpiece,feature or device on a workpiece, etc. that is reflective of theprocessing quality of the processing sequence. The measured dataassociated with an attribute is then used to adjust the process sequenceby analyzing the measured data along with other in-situ processing datathrough the active interdiction control system. For example, themeasured attribute data reflects non-conformities or defects on theworkpiece for providing corrective processing.

FIG. 7A illustrates essentially a single measurement module 716.However, the particular common manufacturing platform 700 mayincorporate a plurality of such measurement modules that areincorporated around one or more workpiece transfer systems, such as theworkpiece transfer module 710. Such measurement modules 716 may bestand-alone modules that are accessed through the transfer module 710like a processing module. Such stand-alone modules will generallyincorporate inspection systems therein that are configured to engage aworkpiece that is positioned in a measurement region of the module andto measure data associated with an attribute of the workpiece.

In an alternative embodiment of the invention, a measurement modulemight be implemented in a measurement region located within a dedicatedarea of an internal space of the transfer chamber defined by thetransfer module 710. Still further, a measurement module might beincorporated wherein at least a portion of the measurement module ispositioned inside of an internal space of a workpiece transfer module,and other components of the measurement module or the specificinspection system of the measurement module are incorporated outside ofthe workpiece transfer module and interfaced through an aperture orwindow into a dedicated area of the internal space that forms themeasurement region in which a workpiece is located or through which aworkpiece will pass.

The measurement modules of the inventive system and platform include oneor more inspection systems that are operable for measuring dataassociated with an attribute of the workpiece. Such data may beassociated with one or more attributes that reflect the quality of theprocessing sequence and the quality of the layers and features anddevices that are being formed on a workpiece. The collected measurementdata is then analyzed, along with processing module data, by an activeinterdiction control system for detecting various non-conformitiesand/or defects on the workpiece or workpiece layers/features. The systemthen provides for corrective processing of the workpiece, such as inupstream or downstream processing modules in the process sequence toameliorate/correct the non-conformities or defects and improve theoverall process.

In accordance with embodiments of the invention, the measurements takenby the measurement module or inspection systems thereof and the datagenerated is associated with one or more attributes of a workpiece. Forexample, the attribute measured may include, for example, on or more of:a layer thickness, a layer conformality, a layer coverage, a layerprofile of a layer on the workpiece, an edge placement location, an edgeplacement error (EPE) for certain features, a critical dimension (CD), ablock critical dimension (CD), a grid critical dimension (CD), a linewidth roughness (LWR), a line edge roughness (LER), a block LWR, a gridLWR, a property relating to selective deposition process(es), a propertyrelating to selective etch process(es), a physical property, an opticalproperty, an electrical property, a refractive index, a resistance, acurrent, a voltage, a temperature, a mass, a velocity, an acceleration,or some combination thereof associated with the fabricated electronicdevices on the workpiece. The list of measured attributes for generatingmeasurement data for the invention is not limited and could includeother attribute data that might be used for processing a workpiece andfabricating devices.

As further discussed herein, the measurement modules and/or inspectionssystems used for providing attribute data may implement a number oftools and methods for measurement for providing the measurement andmetrology of the invention. The measurement modules and/or inspectionssystems may include optical methods, or non-optical methods. Opticalmethods can include high-resolution optical imaging and microscopy(e.g., bright-field, dark-field, coherent/incoherent/partially coherent,polarized, Nomarski, etc.), hyperspectral (multi-spectral) imaging,interferometry (e.g., phase shifting, phase modulation, differentialinterference contrast, heterodyne, Fourier transform, frequencymodulation, etc.), spectroscopy (e.g., optical emission, lightabsorption, various wavelength ranges, various spectral resolutions,etc.), Fourier transform Infrared spectroscopy (FTIR) reflectometry,scatterometry, spectroscopic ellipsometry, polarimetry, refractometers,etc. Non-optical methods can include electronic methods (e.g., RF,microwave, etc.), acoustic methods, photo-acoustic methods, massspectroscopy, residual gas analyzers, scanning electron microscopy(SEM), transmission electron microscopy (TEM), atomic force microscopy(AFM), energy dispersive x-ray spectroscopy (EDS), x-ray photo-emissionspectroscopy (XPS), etc. For example, the inspection system used formeasuring data that is associated with an attribute of the workpiece mayuse one or more of the following techniques or devices: optical thinfilm measurement, such as reflectometry, interferometry, scatterometry,profilometry, ellipsometry; X-Ray measurements, such as X-rayphoto-emission spectroscopy (XPS), X-Ray fluorescence (XRF), X-Raydiffraction (XRD), X-Ray reflectometry (XRR); ion scatteringmeasurements, such as ion scattering spectroscopy, low energy ionscattering (LEIS) spectroscopy, auger electron spectroscopy, secondaryion mass spectroscopy, reflection absorption IR spectroscopy, electronbeam inspection, particle inspection, particle counting devices andinspection, optical inspection, dopant concentration metrology, filmresistivity metrology, such as a 4-point probe, eddy currentmeasurements; a micro-balance, an accelerometer measurement, a voltageprobe, a current probe, a temperature probe for thermal measurements, ora strain gauge. The list of measurement techniques or devices forgenerating measurement data for the invention is not limited and couldinclude other techniques or devices that might be used for obtaining theuseful data for processing a workpiece and fabricating devices inaccordance with the invention.

The measurement modules and/or inspection systems may take measurementson various substrate or workpiece structures passed through theprocessing system including either product workpieces, or non-productsubstrates, i.e., a monitoring substrate. On product workpieces,measurements can be performed on designated target structures, bothdevice-like structures and device-unlike structures, on specified deviceareas, or on arbitrary areas. The measurements may also be performed ontest structures created on the workpiece, that might include pitchstructures, area structures, density structures, etc.

Referring again to FIG. 7A, coupled to the transfer chamber 710 are aplurality of processing modules 720 a-720 d that are configured forprocessing substrates, such as semiconductor or silicon (Si) workpieces.The Si workpieces can, for example, have a diameter of 150 mm, 200 mm,300 mm, 450 mm, or larger than 450 mm. The various processing modulesand measurement modules all interface with the workpiece transfer module710 through appropriate gate access ports with valves G, for example.According to one embodiment of the invention disclosed herein, the firstprocessing module 720 a might perform a treatment process on aworkpiece, and the second processing module 720 b might form aself-aligned monolayer (SAM) on a workpiece. The third processing module720 c may deposit a film on a workpiece by a suitable selectivedeposition process, and the fourth processing module 720 d mayselectively etch or clean a workpiece.

The transfer module 710 is configured for transferring workpiecesbetween any of the processing modules 720 a-720 d and then into themetrology module 716 either before or after a particular processingstep. FIG. 7A further shows the gate valves G that provide isolation atthe access ports between adjacent processing chambers/tool components.As depicted in the embodiment of FIG. 7A, the processing modules 720a-720 d and the metrology module 716 may be directly coupled to thetransfer chamber 710 by the gate valves G and such direct coupling cangreatly improve substrate throughput in accordance with the invention.

The common manufacturing platform 700 includes one or more controllersor control systems 722 that can be coupled to control the variousprocessing modules and associated processing chambers/tools depicted inFIG. 7A during the integrated processing and measurement/metrologyprocess as disclosed herein. The controller/control system 722 can becoupled to one or more additional controllers/computers/databases (notshown) as well. Control system 722 can obtain setup and/or configurationinformation from an additional controller/computer or a server over anetwork. The control system 722 is used to configure and run any or allof the processing modules and processing tools and to gather data fromthe various measurement modules and in-situ data from the processingmodules to provide the active interdiction of the invention. Thecontroller 722 collects, provides, processes, stores, and displays datafrom any or all of the processing modules and tool components. Thecontrol system 722, as described further herein, can comprise a numberof different programs and applications and processing engines to analyzethe measured data and in-situ processing data and to implementalgorithms, such as deep learning networks, machine learning algorithms,autonomous learning algorithms and other algorithms for providing theactive interdiction of the invention.

As described further herein, the active interdiction control system 722can be implemented in one or more computer devices having amicroprocessor, suitable memory, and digital I/O port and is capable ofgenerating control signals and voltages that are sufficient tocommunicate, activate inputs to the various modules of the platform 700,and exchange information with the substrate processing systems run onthe platform 700. The control system 722 monitors outputs from theprocessing system of the platform 700 as well as measured data from thevarious measurement modules of the platform to run the platform. Forexample, a program stored in the memory of the control system 722 may beutilized to activate the inputs to the various processing systems andtransfer systems according to a process recipe or sequence in order toperform desired integrated workpiece processing.

The control system 722 also uses measured data as well as in-situprocessing data output by the processing modules to detectnon-conformities or defects in the workpiece and provide correctiveprocessing. As discussed herein, the control system 722 may beimplemented as a general-purpose computer system that performs a portionor all of the microprocessor-based processing steps of the invention inresponse to a processor executing one or more sequences of one or moreinstructions contained in a program in memory. Such instructions may beread into the control system memory from another computer readablemedium, such as a hard disk or a removable media drive. One or moreprocessors in a multi-processing arrangement may also be employed as thecontrol system microprocessor element to execute the sequences ofinstructions contained in memory. In alternative embodiments, hard-wiredcircuitry may be used in place of or in combination with softwareinstructions for implementing the invention. Thus, embodiments are notlimited to any specific combination of hardware circuitry and softwarefor executing the metrology driver processes of the invention asdiscussed herein.

The active interdiction control system 722 may be locally locatedrelative to the platform 700, or it may be remotely located relative tothe platform 700. For example, the controller 722 may exchange data withthe platform 700 using at least one of a direct connection, an intranetconnection, an Internet connection or a wireless connection. The controlsystem 722 may be coupled to an intranet at, for example, a customersite (i.e., a device maker, etc.), or it may be coupled to an intranetat, for example, a vendor site (i.e., an equipment manufacturer).Additionally, for example, the control system 722 may be coupled toother systems or controls through an appropriate wired or wirelessconnection. Furthermore, another computer (i.e., controller, server,etc.) may access, for example, the control system 722 to exchange datavia at least one of a direct wired connection or a wireless connection,such as an intranet connection, and/or an Internet connection. As alsowould be appreciated by those skilled in the art, the control system 722will exchange data with the modules of the common manufacturing platform700 via appropriate wired or wireless connections. The processingmodules may have their own individual control systems (not shown) thattake input data for control of the processing chambers and tools andsub-systems of the modules and provide in-situ output data regarding theprocess parameters and metrics during the processing sequence.

With specific reference to FIGS. 7A and 7B, and in accordance with oneembodiment, measurement data may be obtained in a measurement/metrologymodule 716 that is a separate module on the platform 700 coupled to thetransfer module 710. Generally, the transfer module 710 has a chamberthat incorporates one or more transfer mechanisms or robots 714 thatwill handle and move workpieces through the internal space of thechamber and into and out of the processing module in the processingsequence.

More specifically, the transfer mechanism 714 is positioned inside ofthe internal space 713 of the transfer module 710 that can define acontrolled environment and is configured for moving the workpiecesthrough the internal space and environment and selectively in and out ofthe plurality of processing modules 720 a-720 d and the measurementmodules 716 or into and out of a measurement region in a dedicated areaof the internal space in order for a measurement inspection system tomeasure data. In accordance with one feature of the invention, becausethe internal space 713 of the transfer module 710 and processing modules720 a-720 d and measurement modules 716 are coupled together on thecommon manufacturing platform 700, the controlled environment may bemaintained for the workpiece generally through most of or all of themeasurement and processing sequence. Such a controlled environment couldinvolve a vacuum environment or an inert gas atmosphere in the transfermodule or measurement module.

The transfer module 710 includes a plurality of access ports or sideports, each with a suitable gate G, through which a workpiece is movedto and from the plurality of processing modules 720 a-720 d. To providethe necessary processing sequence for efficient through-put on platform700, the plurality of processing modules 720 a-720 d includes modulesthat handle a variety of workpiece processing steps on the commonplatform, including one or more etching modules and one or morefilm-forming or deposition modules. The measurement module 716, asillustrated in FIG. 7A is coupled with the transfer module 710 also atone of the side or access ports through a suitable gate G. In otherembodiments, the measurement module is coupled with the transfer moduleat a port formed in the top of the transfer module. In still furtherembodiments as described herein, the transfer module acts as ameasurement module as well wherein at least a portion of the measurementmodule for capturing measurement data is incorporated or positionedinside of an internal space of the transfer module. The transfermeasurement module (TMM) in such an embodiment, as illustrated in FIGS.7C-7D, includes a measurement region located within a dedicated area ofthe internal space of the transfer module.

The active interdiction control system 722 collects workpiecemeasurement data generally on-the-fly as the substrate moves in theprocessing sequence between one or more of the processing modules andthe measurement/metrology module 716. The data is captured and thenanalyzed and processed to detect non-conformities and defects andprovide corrective processing as discussed herein. The activeinterdiction control system 722 provides the necessary control of theprocessing steps of the sequence to make control adjustments to variousfabrication processing steps as performed in order to correct for thedetected non-conformities/defects. Adjustments may be made to processsteps and processing modules that precede or are upstream of thecaptured measurement data and/or process steps that follow or aredownstream of the measurement data in sequence. Alternatively, asuitable corrective action or corrective processing might includeejection of the workpiece from the platform 700 in order to not wastefurther time and materials on a workpiece which cannot be saved.

Referring to FIG. 7B, one exemplary measurement module 716 isillustrated that incorporates an inspection system 730 for makingmeasurements on the workpiece in real-time with respect to theprocessing sequence executed on common manufacturing platform 700.

The inspection system 730 measures data associated with an attribute ofthe workpiece, as discussed herein. The inspection system 730incorporates one or more signal sources 732 that direct a measurementsignal 734 toward a workpiece 736. Incident signals 734 are reflected orscattered from the surface of the workpiece 736 and the scatteredsignals 735 are captured by the detector 740. The detectors 740 generatemeasurement data 750 which may then be directed to the activeinterdiction control system 722 as described herein. In one embodiment,the workpiece 736 is positioned by transfer mechanism 714 on ameasurement platform 738 that may be translated side-to-side and up anddown and rotated as indicated by the arrows in FIG. 7B so that ameasurement signal 734 may be directed to various proper positions onthe workpiece 736.

That is, in the embodiment of FIG. 7B, the measurement module includes aseparate support mechanism 738 for supporting a workpiece 736 positionedin the measurement module 716. The inspection system engages the supportmechanism 738 for measuring data associated with a workpiece attributesupported on the support mechanism. In such a scenario, the supportmechanism 738 in the measurement module 716 is generally separate fromthe transfer mechanism that otherwise moves the workpiece 736 andpositions it on the support mechanism.

The separate support mechanism translates the workpiece 736, such asthrough vertical and/or horizontal movement and also may rotate theworkpiece 736 to provide at least two degrees of freedom for measuringdata associated with an attribute of the workpiece 736 as discussedherein. The support mechanism may also incorporate a temperature controlelement therein for controlling workpiece temperature. Therefore, in theembodiment of FIG. 7B, the support mechanism provides the support andmovement of the workpiece 736 necessary for the measurement of dataafter the workpiece 736 is positioned thereon by the transfer mechanism.In an alternative embodiment, the transfer mechanism may provide thefunction of supporting and moving the workpiece 736 for engagement withthe inspection system 730 for measuring data associated with anattribute on the workpiece 736.

The captured measurement data 750 may then be directed to control system722 and further evaluated and analyzed to determine a particular actionfor the measured workpiece. If the measurement data indicates that themeasured parameters are within specification of the desired design andfabrication process, and/or there are no actionable detected defects,the workpiece may proceed as normal through the process flow within theplatform 700. Alternatively, if the measured data 750 indicates that theworkpiece is beyond correction or amelioration, the workpiece might beejected from further processing. Alternatively, in accordance with anembodiment of the invention, the active interdiction control system 722may analyze the data and provide corrective processing as one or morecorrective steps to be taken for that workpiece or to be made in variousprocess steps of the overall process flow in order to correct thecurrent workpiece, and also to prevent the need for corrective action inother workpieces that are subsequently processed on the platform 700.Specifically, referring to FIG. 7B, the active interdiction controlsystem 722 may incorporate one or more processing steps and processingcomponents therein for yielding correction to the process flow. First,the necessary measurement data 750 may be captured and pre-processed asillustrated by block 754. Next, modeling and data analysis occurs on thecaptured data as well as any in-situ processing data associated with oneor more of the processing modules and process steps as indicated byblock 756. The modeling and analysis may utilize artificialintelligence, including deep learning and autonomous learning programsand components. Next, the analysis may provide corrective processcontrol wherein one or more of the processing steps and processingmodules are controlled to correct or ameliorate perceived or detectednon-conformities or defects in the layers and features that are out ofspecification with respect to the overall design for the workpiecefabrication. The corrective process control of block 758 may be providedto one or more of the processing steps or processing modules and it maybe applied to one or more processing steps that are previous in time(upstream) to the capture of the measurement data 750 or may be appliedto one or more of the process steps to follow (downstream) the captureof the measurement data 750 within the overall substrate fabricationaccording to the desirable design. The active interdiction controlsystem 722, and its processes as indicated by blocks 754, 756 and 758may be incorporated in software run by one or more computers of thecontrol system 722 and/or components of that system.

In accordance with embodiments of the invention, the inspection systemsfor obtaining measurement data engage the workpiece by performingcontact measurement or metrology or non-contact measurement or metrologydepending on the attribute measured or the type of measurement. Acombination of both contact and non-contact measurement might be used.Depending on the location of the inspection system, portions of theinspection system may be positioned partially or entirely inside aninternal space or chamber of a module. In the embodiment of FIG. 7A asdisclosed herein, dedicated measurement modules 716 may entirely containthe inspection system. Alternatively, a portion of a measurement modulemight be positioned inside of an internal space of a chamber, such asinside an internal space of a workpiece transfer module, with anotherportion of the measurement module located outside of the chamber. Suchan embodiment is illustrated in FIG. 7D for example wherein a transfermeasurement module is illustrated using a measurement region locatedwithin a dedicated area of the transfer chamber internal space and theinspection system is configured for engaging a workpiece positioned inthe measurement region for measuring data associated with an attributeon the workpiece.

Support mechanism 738 or transfer mechanism 714 holding workpiece 736may be translated and rotated to provide measurements of various areason the workpiece 736. In that way, measurement data may be captured atvarious portions or segments of the entire workpiece. Thus, continuousmeasurements or point-by-point measurements are possible therebyreducing the overall measurement time and processing time.

For example, the inspection system measures data over a portion of theworkpiece that is equal to or exceeding 1 square centimeter.Alternatively, the inspection system measures or images a substantiveportion of the workpiece that is equal to or exceeding 90% of theworking surface area of the workpiece. As noted, the inspection systemmay perform a measurement at plural discrete locations on the workingsurface of the workpiece or may perform a continuous sequence ofmeasurements across a portion of the workpiece. For example, theinspection system may perform a measurement along a path extendingacross or partially across the workpiece. Such a path may include aline, a sequence of lines, an arc, a circular curve, a spiral curve, anArchimedean spiral, a logarithmic spiral, a golden spiral, or somecombination thereof. Also, there may be several inspection systemswherein source/detector pairs 732, 740 may each represent a differentinspection signal from a different inspection system and may bedifferent forms of signals. For example, one source/detector pair 732,740 might use an optical signal while another source/detector pair 732,740 might use an electromagnetic signal, depending on the inspectionsystem.

The inspection system(s) can perform multiple measurements of attributeson a workpiece while the workpiece is in a measurement module or indedicated area of a transfer measurement module as discussed herein. Themeasurements may be made simultaneously in time. That is, differentinspection systems might make measurements at the same time.Alternatively, the various inspection systems might operate at differenttimes. For example, it may be necessary to move or position theworkpiece in one position for one type of measurement or inspectionsystem, and then move or position the workpiece for another measurementby the same or a different type of inspection system.

The inspection system(s) may be non-contact systems for providingnon-contact measurement and metrology. Alternatively, one or moreinspection systems of a measurement module or transfer measurementmodule might use a contact sensor that may be moved and positioned at asurface of the workpiece to make a measurement. The inspection systemsprovided in accordance with the invention may incorporate a combinationof contact inspection systems and non-contact inspection systems forgathering measurement data associated with an attribute of theworkpiece.

As described above, the inspection system as implemented in ameasurement module or in a transfer measurement module may be stationarywhile the support mechanism or workpiece transfer mechanism moves theworkpiece to engage with the inspection system and to take measurementsin different areas of the workpiece. Alternatively, the inspectionsystem 730, or some portion thereof, is movable with respect to theworkpiece support mechanism 738, the workpiece transfer mechanism 714and the module. The inspection system might be configured to translateand/or rotate with respect to the stationary workpiece to obtainmeasurement data from areas of the workpiece.

In other embodiments of the invention, the inspection system may beembedded in or part of a workpiece support mechanism. The inspectionsystem 730 might be mounted or supported on the support mechanism 738.Then, when the workpiece is positioned on the support mechanism, it willbe in a proper position for engagement by the inspection system. Aninspection system 730 might be embedded in the support mechanism so asto sit below or otherwise proximate to a positioned workpiece to providemeasurement data associated with a mass measurement or a temperaturemeasurement of the workpiece, for example.

FIG. 7C illustrates a common manufacturing platform 700′ incorporating atransfer module 710′ in accordance with one embodiment the inventionthat utilizes a dedicated area to form a measurement region whereinmeasurement data may be gathered from a workpiece during transit. Inthat way, as noted herein, the workpiece can be processed and measuredwhile remaining within a controlled environment, such as a vacuumenvironment. The workpiece does not need to leave the environment of theplatform 700′ for determining how the process is proceeding and fordetecting any non-conformities or defects. Accordingly, the embodimentas illustrated in FIG. 7CA forms a transfer measurement module (TMM)that may be utilized with one or more processing modules or as part of acommon manufacturing platform. Furthermore, multiple transfermeasurement modules may be utilized and interfaced together to cooperateand form a larger common manufacturing platform.

The inspection systems incorporated within a transfer measurement module(TMM) operate in and are similar to other inspection systems asdescribed herein. Such inspection systems as illustrated in FIG. 7D, forexample, only illustrate certain inspection systems. However, otherinspection systems and features, such as those discussed above, wouldalso be applicable to the transfer mechanism module is illustrated inFIG. 7C. As such, some common reference numerals are utilized in FIGS.7C-7D as previously discussed herein.

The platform 700′ incorporates a workpiece transfer module 710′ thatprovides measurement/metrology data. The transfer measurement module(TMM) 710′ includes a workpiece transfer mechanism, such as in the formof a handling robot 714 within the internal space of a transfer chamber713. The transfer mechanism 714 is operable as in platform 700 to moveone or more or more workpieces through the transfer module 710′ andbetween various of the processing modules that are coupled to transfermodule 710′ in the common manufacturing platform. In accordance with onefeature of the invention, transfer chamber 713 defines an internal spacethat includes a dedicated area that is used for measurement. Themeasurement region 715 of the TMM 710′ is located in the dedicated area.The measurement region/area 715 is proximate to one or more inspectionsystems 730 for measurement.

More specifically, the measurement region 715 is positioned within thetransfer chamber 713 so as to not interfere with the primary purpose ofthe transfer measurement module in moving workpieces through the processsequence and into and out of various processing modules. The measurementregion defines one or more positions for placement of a workpiece formeasurement. To that end, one or more inspection systems are configuredto engage a workpiece that is positioned in the measurement region ofthe transfer chamber 713. The inspection system is then operable formeasuring data associated with an attribute on the workpiece inaccordance with the invention. As noted with the inspection systemsdisclosed herein, a support mechanism might be located within themeasurement region 715 for supporting a workpiece during the collectionof measurement data by the inspection system. Alternatively, thetransfer mechanism 714 may provide the positioning and support of theworkpiece within the measurement region 715 of the transfer chamber. Inaccordance with embodiments of the invention, the workpiece can be movedinto or through the measurement region 715 during a processing sequenceto obtain measurement data from one or more inspection systems that areassociated with that measurement region. While a single measurementregion is illustrated in FIG. 7C for illustrative purposes, multiplemeasurement regions 715 might be incorporated into the TMM 710′.

Referring to FIG. 7D, the TMM module 710′ incorporates one or moreinspection systems 730 located within a measurement region 715 andprovides the ability to obtain real-time measurements and measurementdata during a processing sequence. In one embodiment, measurement region715 within the TMM 710′ incorporates a support mechanism 738 thatreceives a workpiece from mechanism 714 for measurement inside chamber713. Measurement data is captured as the workpiece is moved betweenprocessing modules. As discussed above, alternatively, the transfermechanism or robot 714 might actually act as a support mechanism formoving the workpiece with respect to the inspection system 730 in theTMM 710′. Still further, the inspection system 730 in the TMM 710′ mightalso incorporate a stationary workpiece wherein the inspection system730 itself moves. Similarly, the inspection system 730 might beincorporated as part of or embedded with the support mechanism.

The measurement module or inspection system 730 may be entirelycontained in the TMM 710′ to make measurements. In other embodiments, aleast a portion of the measurement module or inspection system ispositioned inside of an internal space of the TMM 710′ so as to define ameasurement region within a dedicated area of the internal space asshown in FIG. 7D, while other portions may reside outside the TMM 710′.More specifically, measurement region 715 is defined and is locatedwithin a dedicated area of the internal space of the transfer chamber713. The signal source and signal detector elements of inspection system730 may be located externally of the transfer chamber internal space 713while the workpiece support mechanism 738 and transfer mechanism 714 forsupporting a workpiece 736 are contained within the transfer chamber713. To that end, the inspection signals 734 pass through an appropriateaccess port 742 that is effectively transparent to the passage of theinspection signal 734 from the inspection system 730 and into theinternal space 713 to engage workpiece 736 positioned in the measurementregion 715. As noted, the inspection signal 734 might include anelectromagnetic signal, an optical signal, a particle beam, a chargedparticle beam, or some combination of such signals. The access port 742may be appropriately formed to operate with a specific inspection systemand the sources of the inspection signal. For example, the access port742 might include a window, an opening, a valve, a shutter, and iris, orsome combination of different structures for forming the access port inorder to allow incident inspection signals to engage the workpiece 736.To that end, at least a portion of the inspection system 730 might belocated generally above a top surface of the transfer chamber 713.

While the present invention has been illustrated by the description ofone or more embodiments thereof, and while the embodiments have beendescribed in considerable detail, they are not intended to restrict orin any way limit the scope of the appended claims to such detail.Additional advantages and modifications will readily appear to thoseskilled in the art. The invention in its broader aspects is thereforenot limited to the specific details, representative apparatus and methodand illustrative examples shown and described. Accordingly, departuresmay be made from such details without departing from the scope of thegeneral inventive concept.

What is claimed is:
 1. A method of selective deposition on asemiconductor workpiece using an integrated sequence of processing stepsexecuted on a common manufacturing platform hosting a plurality ofprocessing modules including one or more film-forming modules, one ormore etching modules, and one or more transfer modules, the integratedsequence of processing steps including: receiving a workpiece into thecommon manufacturing platform, the workpiece having a target surface ofa first material and a non-target surface of a second material differentthan the first material; depositing an additive material on theworkpiece in one of the one or more film-forming modules, wherein thedepositing is with selectivity relative to the non-target surface thatresults in a layer of the additive material forming on the targetsurface at a higher deposition rate than on the non-target surface;etching the workpiece in one of the one or more etching modules toremove additive material from the non-target surface; and repeating thedepositing and etching until the layer of additive material reaches atarget thickness, wherein the integrated sequence of processing steps isexecuted in a controlled environment within the common manufacturingplatform and without leaving the controlled environment, and wherein theone or more transfer modules are used to transfer the workpiece betweenthe plurality of processing modules while maintaining the workpiecewithin the controlled environment.
 2. The method of claim 1, furthercomprising: within the controlled environment, obtaining measurementdata related to one or more attributes of the workpiece and, based onthe measurement data, determining whether a defectivity, thickness,uniformity, and/or selectivity of the additive material on the workpiecemeets a target condition.
 3. The method of claim 2, wherein theplurality of processing modules includes a correction module, the methodfurther comprising: when the defectivity, thickness, uniformity, and/orselectivity of the additive material on the workpiece is determined tonot meet the target condition, processing the workpiece in thecorrection module to remove at least a portion of the additive materialfrom at least one of the target surface or the non-target surface. 4.The method of claim 2, wherein the one or more transfer modules furtherinclude a workpiece measurement region located within a dedicated areaof at least one of the one or more transfer modules, and wherein theobtaining measurement data is performed during at least one of thetransfers of the workpiece between the plurality of processing modulesby passing the workpiece into the workpiece measurement region.
 5. Themethod of claim 2, wherein the common manufacturing platform includesone or more metrology modules, and wherein the obtaining measurementdata is performed by transferring the workpiece into the metrologymodule between one or more of the processing steps of the integratedsequence of processing steps.
 6. The method of claim 2, wherein the oneor more attributes include attributes of the target surface prior todepositing the additive material, attributes of the non-target surfaceprior to depositing the additive material, attributes of the layer ofadditive material after depositing the additive material, attributes ofthe non-target surface after depositing the additive material,attributes of the layer of additive material after etching theworkpiece, or attributes of the non-target surface after etching theworkpiece.
 7. The method of claim 6, wherein the one or more attributesinclude an amount of voids on the target surface, an amount of additivematerial on the non-target surface, a loss of selectivity, a profile ofthe additive material, an amount of the additive material on one regionof the workpiece relative to an amount of the additive material onanother region of the workpiece, or a combination of two or morethereof.
 8. The method of claim 1, wherein the target surface and thenon-target surface form a planar surface, and wherein depositing theadditive material on the target surface forms an elevated feature abovethe planar surface.
 9. The method of claim 1, wherein the target surfaceis an exposed bottom surface in a recessed feature formed in the secondmaterial, and wherein depositing the additive material on the targetsurface is a bottom-up deposition to at least partially fill therecessed feature, and wherein etching the workpiece includes removingthe residue deposited as a contaminant on an upper planar surface of thesecond material adjacent to the recessed feature.
 10. The method ofclaim 1, wherein the integrated sequence of processing steps furthercomprises pre-treating the workpiece before depositing the layer ofadditive material to alter a surface termination of the target surface,or a surface termination of the non-target surface, or a combinationthereof, and wherein the plurality of processing modules hosted on thecommon manufacturing platform includes one or more pre-treatment modulesfor performing the pre-treating in the controlled environment.
 11. Themethod of claim 10, wherein the pre-treating includes applying aself-assembled monolayer on the non-target surface to inhibit depositionof the additive material on the non-target surface and to provide theselectivity on the target surface relative to the non-target surface.12. The method of claim 11, wherein the etching includes removing theself-assembled monolayer.
 13. The method of claim 11, wherein the firstmaterial is a first dielectric material, the second material is a metal,and the additive material is a second dielectric material.
 14. Themethod of claim 11, wherein the first material is a metal, the secondmaterial is a first dielectric material, and the additive material is asecond dielectric material, or wherein the first material is adielectric material, the second material is a first metal, and theadditive material is a second metal.
 15. The method of claim 1, whereinthe first material is a first metal, the second material is a dielectricmaterial, and the additive material is a second metal.
 16. The method ofclaim 15, wherein the integrated sequence of processing steps furthercomprises selectively forming a barrier layer on the non-target surfaceof dielectric material relative to the target surface of the firstmetal, such that more metal regions of the target surface are exposedthan dielectric regions of the non-target surface, and depositing theadditive material of the second metal on the workpiece increases aninitial step-height between the metal regions of the target surface andthe dielectric regions of the non-target surface based, at least inpart, on the selective formation of the barrier layer.
 17. The method ofclaim 1, further comprising: obtaining measurement data related to oneor more attributes of the workpiece in a workpiece measurement regionlocated within a dedicated area of at least one of the one or moretransfer modules or within a metrology module hosted on the commonmanufacturing platform, the measurement data being obtained after atleast one of the processing steps of the integrated sequence ofprocessing steps; and when the measurement data indicates an attributeof the one or more attributes is non-conforming, performing a correctiveaction on the workpiece to remove, minimize, or compensate for thenon-conforming attribute prior to performing a next processing step inthe integrated sequence of processing steps.
 18. The method of claim 17,wherein the integrated sequence of processing steps further comprisespre-treating the workpiece before depositing the layer of additivematerial by applying a self-assembled monolayer on the non-targetsurface to inhibit deposition of the additive material on the non-targetsurface, and wherein performing the corrective action comprises one ormore of the following: removing the self-assembled monolayer when thenon-conforming attribute is based, at least in part, on incompletecoverage of the non-target surface by the self-assembled monolayer or anamount of exposed area of the non-target surface being greater than apredetermined exposed area threshold; removing at least a portion of thelayer of additive material when the non-conforming attribute is based,at least in part, on a step-height distance between the target surfaceand the non-target surface being less than a predetermined step-heightthreshold or an amount of exposed area of the non-target surface beingless than the predetermined exposed area threshold; adding furtheradditive material to the workpiece when the non-conforming attribute isbased, at least in part, on a thickness of the additive materialoverlying the target surface being less than a predetermined thicknessthreshold; etching the workpiece when the non-conforming attribute isbased, at least in part, on a remaining additive material on thenon-target surface or a remaining self-assembled monolayer on thenon-target surface being greater than a predetermined remainingthickness threshold; or treating the workpiece when the non-conformingworkpiece attribute is based, at least in part, on a reflectivity fromthe workpiece being less than a predetermined reflectivity threshold,wherein the treating is a temperature treatment, a plasma etchtreatment, or combination thereof.
 19. The method of claim 17, whereinthe integrated sequence of processing steps further comprises, prior todepositing the additive material, etching the target surface to removesurface contamination, and selectively forming a barrier layer on thenon-target surface relative to the target surface, such that moreregions of the target surface are exposed than regions of the non-targetsurface, and wherein performing the corrective action comprises one ormore of the following: removing the barrier layer when thenon-conforming attribute is based, at least in part, on incompletecoverage of the regions of the non-target surface by the barrier layeror an amount of exposed area of the non-target surface is greater than apredetermined exposed area threshold; removing at least a portion of thelayer of additive material when the non-conforming attribute is based,at least in part, on a step-height distance between the target surfaceand the non-target surface being less than a predetermined step-heightthreshold or an amount of exposed area of the non-target surface beingless than the predetermined exposed area threshold; adding furtheradditive material to the workpiece when the non-conforming attribute isbased, at least in part, on a thickness of the additive materialoverlying the target surface being less than a predetermined thicknessthreshold; etching the workpiece when the non-conforming attribute isbased, at least in part, on a remaining additive material on thenon-target surface or a remaining barrier layer on the non-targetsurface being greater than a predetermined remaining thicknessthreshold; or treating the workpiece when the non-conforming workpieceattribute is based, at least in part, on a reflectivity from theworkpiece being less than a predetermined reflectivity threshold,wherein the treating is a temperature treatment, a plasma etchtreatment, or combination thereof.
 20. The method of claim 1, whereinthe one or more film-forming modules include a vacuum environment, andthe one or more transfer modules transfer the workpiece into and out ofthe one or more film-forming modules without breaking vacuum.